PUMPS

Your foundational guide to understanding, selecting,

and operating pumps.

Adham el-Desouqy

https://www.linkedin.com/in/adham-el-desouqy/
 Table of
CONTENTS
01 Introduction
includes Pumps definition & classification

02 Key concepts
including important terms like priming, slip,
suction line, discharge line & others.

Pumps
03 discussing different types of pumps, their
mechanisms, components, P&ID symbols and
more.

04 common problems
including problems facing pumps like vapor
lock & Cavitation, what causes them and how
to face them.

05 performance curves
discussing pumps performance curve and
selection criteria according to the curves.
Introduction
Pumps are essential equipment used to move fluids from one point to another.
They create pressure to overcome resistance and force the fluid to flow. This
pressure can be generated through various mechanisms, such as mechanical
rotation, positive displacement, or centrifugal force.

 Classification of Pumps
Any pump is generally classified in one of the following two major classes.

1. Dynamic Pumps:
o These pumps use a rotating impeller to generate centrifugal force,
which accelerates the fluid outward and creates pressure.
Examples include centrifugal pumps, and axial pumps.
2. Positive Displacement Pumps:
o Rotary Pumps:
These pumps use rotating elements to displace the fluid.
Examples include gear pumps, vane pumps, screw pumps, and lobe
pumps.
o Reciprocating Pumps:
These pumps use a piston or plunger to create a pressure difference.
Examples include piston pumps, plunger pumps, and diaphragm
pumps.

 Special Purpose Pumps:

o Vacuum Pumps: These pumps remove air or other gases from a closed
space.
o Peristaltic Pumps: These pumps use a flexible tube and rollers to
transport the fluid.
o Jet Pumps: These pumps use a high-velocity jet of fluid to create a
vacuum or suction.

The choice of pump depends on factors such as the fluid properties, flow rate,
pressure requirements, and application. Understanding the several types of
pumps and their characteristics is crucial for selecting the right pump for a
specific task.

1
Key concepts & notes
 pumps are designed to handle liquids only, not gases or multi-phase
fluids. Feeding gas to a liquid pump can cause severe damage discussed
later.

 Compression Vs pressurization.
As we mentioned previously, pumps job is to increase the pressure of a liquid,
but aren’t liquids incompressible? Here lies a common misconception between
compression and pressurization.

Compression emphasizes reducing the volume of a substance through

mechanical force. It is common in hydraulic systems, refrigeration, and data
compression, in this sense, liquids are incompressible.

Pressurization focuses on increasing pressure to a specific level. It can be

achieved through compression, heating, or chemical reactions which is the
right method used by pumps to increase a liquid’s pressure.

 Suction & Discharge lines

Suction and discharge lines are essential components of pumps.
The suction line or the pump inlet draws fluid into the pump, while the
discharge line or outlet pushes fluid out of the pump. Together, they enable
pumps to transport fluids from one location to another.

 Lines accessories
 strainer is often placed on the suction line to prevent debris from
entering the pump and causing damage.
 Pipe fittings Used to connect pipes & pump including elbows, tees,
couplings, and reducers.
 Pressure gauges Measure the pressure of the fluid being pumped &
used to monitor the pump's performance and detect any problems.
 Suspension devices Used to support the pump and prevent
vibration especially important for large or heavy pumps.
 Check valves Prevent backflow of fluid.
 Isolation valves Allow for maintenance or repairs on a section of a
pipe without affecting the rest of the system.
 Pressure switches Control the pump's operation based on
pressure.

2
  Priming
as we mentioned earlier, pump’s suction line should only contain liquid to avoid
problems like vapor lock and cavitation while operating the pump.
priming is done at the start of the pump operation to ensure full liquid flow by
applying the following procedure:

1-Prepare the system

Ensure proper lubrication.
Provide cooling water.
Check liquid level.
Open suction line valves.
Close discharge line valves and drain valves.

2-Vent gas
Open discharge vent valve until uniform liquid flow.

3-Start the pump

Start the motor.
Confirm discharge pressure increases.
Slowly open discharge valve until fully open.

4-Monitor
Observe flowrate, leakage, and pump condition.

3
  Bleed valve
Crucial for pump systems, especially in priming. They remove trapped air and
fill the pump with liquid, preventing cavitation. Bleed valves can be manual,
automatic, or combined with vent valves. They are usually located at the
highest point of the suction line and require regular maintenance.

 Slip%
Pump slip refers to the loss of pumping capacity due to fluid leaking back
through the pump from the discharge side to the inlet side. This internal
backflow reduces the pump's efficiency and can affect its overall performance.
to reduce the slip% Maintain proper operating conditions Avoiding excessive
pressure, flow rate, or speed.

 Continuity equation
this principle is based on the mass conservation law & it simply states that if the
fluid's density remains constant (incompressible flow), then the product of the
cross-sectional area and velocity must be the same at any two points along a
flow path, hence the cross-sectional area and the flow velocity are inversely
proportional.

And according to the energy conservation law, we never lose energy, so if the
area gets bigger and the velocity drops, the difference between kinetic energy
before and after is converted into pressure energy which is basically how every
pump raises pressure energy.

ṁin = ṁout
ṁ = ρAv
ρA₁v₁ = ρA₂v₂
A₁v₁ = A₂v₂

4
  Pressure head
Pressure head is basically the height of a column of fluid that would exert the
same pressure as the fluid at a specific point.
it’s directly proportional to the pressure according to equation P=ρgh

 Pump pressure heads

for a pump system exists 5 types of pressure heads

 Suction head (hps)

representing the pressure required to convey the liquid into the
pump intake, gets a positive sign.
 Static head (hs)
representing the vertical distance between the liquid surface and the
pump suction flange, if the liquid is above the pump level, it gets a
positive sign and vice versa, it’s neglected if the liquid is at the level
of the pump.
 Vapor pressure head (hvp)
representing the pressure exerted by the vapor proportion of the
liquid at a given temperature.
 Friction head (hf)
representing the energy lost due to friction as the liquid flows
through the suction line, gets a negative sign.
 Net positive suction head available (NPSHa)
representing the net of the previous heads as follows
NPSHa=hps+hs-hvp-hf

 Net positive suction head required (NPSHr)

It represents the minimum pressure required at the pump's suction port to
prevent pump problems like cavitation and vapor lock
so, NPSHa should be bigger than NPSHr.
NPSHr is typically provided by the pump manufacturer, it depends on the
pump's design, impeller shape, and operating conditions.

5
  Minimum flow line.
A minimum flow line is a crucial component in pump systems,
Its primary purpose is to protect the pump from damages (later discussed in
detail) that can occur when operating at low or no flow rates.

Every pump is designed to work above a certain capacity to avoid Cavitation,

(later discussed in detail) is a phenomenon that occurs when a liquid is subjected to
low pressure conditions (NPSHa<NPSHr), causing it to vaporize into bubbles.
These bubbles then collapse violently damaging the pump.

operating in a very low capacity leads to cavitation in two manners, directly as it

means a lower NPSHa and indirectly as it causes overheating due to excessive
and unnecessary power consumption and easier vaporization as a result.

resulting excessive overheating can also lead to thermal expansion of the

pump parts.

How Does a Minimum Flow Line Work?

A minimum flow line is essentially a bypass loop controlled using a valve or a
flow control device

such cycle simply recirculates a portion of the pump's discharge back to its
suction ensuring the pump always has a minimum flow rate, even when the
system demand is low.

notes:
-The min flow line itself should be designed as long as possible to get rid of the
heat generated from the pump outlet.

-The recirculation loop trick does not increase the overall flow in the piping
system but ensures the pump's minimum flow requirement is met.

-Not all centrifugal pumps require a minimum flow control loop, especially small
pumps that are less expensive.

- Minimum flow line is merely a preventive measure, not a cure for existing
problems.

6
Example

let's assume that this pump has a capacity of 150 cubic meters per hour the
Designer specified that the minimum capacity is 100 cubic meters per hour we
can provide a recirculation line from the outlet of the pump back into the inlet
line as seen.

if the flow rate into the pump is 125 cubic meters per hour the pump is
operating safely above the minimum flow rate specified as 100 cubic meters
per hour in this case the sensor on the pump outlet sends a signal to the
control valve on the recirculation line and it remains closed.

However, if the flow drops to less than 100 cubic meters per hour, the sensor
on the pump outlet sends a signal to the control valve to open allowing a
sufficient amount of the flow to recirculate back to the pump so that its suction
is at a safe & acceptable flow rate.

7
Pumps
In this section we’ll explore different pumps including their main components,
mechanism, applications, classifications, p&id symbols and more.

Let’s discuss pumps as we initially classified them into dynamic and positive
displacement

1. Dynamic pumps
Dynamic pumps, also known as kinetic pumps, are a type of pump that uses
kinetic energy to move liquids.

They work by increasing the velocity of the fluid, which then converts into
pressure energy as the velocity decreases in a process known as the Bernoulli
principle.

The Bernoulli principle is a fundamental principle in fluid dynamics that describes

the relationship between the pressure, velocity, and elevation of a fluid. It states
that as the velocity of a fluid increases, its pressure decreases.

There are two major types of dynamic pumps, centrifugal pumps & axial pumps.

 Centrifugal pumps
The most common type of dynamic pump, they use a centrifugal force to
increase the fluid's velocity, they are widely used in various industries

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Key Components
1. Impeller:
This is the rotating component at the heart of the pump. It has a series of
vanes or blades that impart kinetic energy to the fluid.

Impeller Types in Centrifugal Pumps

TYPE DESCRIPTION QUALITIES APPLICATIONS

Blades open on High flow rate, low Low-viscosity liquids
OPEN both sides. head pressure, (water, wastewater…).
easier to clean
One side Balanced flow and General-purpose
SEMI-OPEN enclosed by a head. applications.
shroud.
Both sides High head pressure, Thick fluids, slurries,
CLOSED enclosed by efficient, reliable, high-pressure
shrouds. well supported applications.

2. Volute casing:
The casing surrounds the impeller and directs the flow of fluid.
It has a volute shape to gradually increase the area of flow, hence
reducing flow velocity increasing the pressure according to the Bernoulli
principle as discussed earlier as the liquid moves from the impeller to the
discharge port.
3. Driving motor:
provides the mechanical energy necessary to move the impeller and pump
the fluid, its type depends on the specific application.
4. Shaft:
The shaft connects the impeller to the motor or other driving mechanism
conveying the mechanical kinetic energy to the impeller.
5. Suction Pipe: This pipe connects the pump to the fluid source drawing fluid
into the pump.
6. Discharge Pipe: This pipe carries the pressurized fluid away from the pump
to its intended destination.
7. Mechanical seals: This seals the shaft to prevent leakage of fluid.
8. Wear rings (packings): hold the shaft firmly against the casing.
9. Drain: allows drainage of the pump liquid when needed.

9
Shaft connected to an impeller

Seal

Packing

10
Working mechanism
1. Fluid Intake:
Fluid is drawn into the pump through the suction pipe.
2. Impeller Rotation:
The impeller rotates, driven by an external power source via shaft.
3. Centrifugal Force:
As the impeller rotates, the fluid is subjected to centrifugal force, which
pushes it outward towards the casing.
4. Velocity Increase:
The fluid's velocity increases as it is forced outward by the impeller.
5. Pressure Conversion:
As the fluid moves from the impeller towards the discharge port, its
velocity decreases. This decrease in velocity converts kinetic energy
into pressure energy.
6. Discharge:
The pressurized fluid is discharged from the pump through the
discharge pipe.

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Centrifugal pumps classifications
1-According to the number of impellers:
Single-Stage: Has a single impeller.
Multi-Stage: Has multiple impellers arranged in series to increase pressure.

2-According to the position of the shaft:

Horizontal: the more common option.
Vertical: a more compact option for smaller available areas, used for near
boiling point cases.

Vertical pumps are better suited for handling boiling liquids than horizontal
pumps. This is because:

Vapor lock prevention:

Vertical pumps are less likely to experience vapor lock, which occurs when
vapor accumulates in the pump, preventing liquid flow.

Reduced cavitation:
Cavitation, the formation and collapse of vapor bubbles, can damage pumps.
Vertical pumps have a lower risk of cavitation.

Easier maintenance:
Vertical pumps are generally easier to access and maintain.

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3-According to the number of the suction inlets:
Thrust force is a common issue in centrifugal pumps, especially those with high
flow rates or high pressures because of imbalance of forces at the inlet, using
double inlet pumps is a way of thrust resistance

By having multiple inlets, these pumps can create a more balanced force
distribution on the impeller, minimizing the radial force imbalance that often
contributes to thrust.

Additionally, the multiple inlets can sometimes generate a counteracting thrust

force that helps to offset the main thrust. While multi-suction pumps can be
beneficial in reducing thrust, it's important to consider other factors, such as
the specific pump design and operating conditions, to ensure optimal
performance and avoid excessive thrust.

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  Axial pumps
An axial pump is a dynamic pump in which the fluid flows axially through the
pump, parallel to the shaft, converting the kinetic energy from the propeller
into pressure energy, it can be installed vertically or horizontally.

Key Components

1. propeller:
This is the rotating component that imparts energy to the fluid.
It has straight blades that are angled to force the fluid to move
axially.
2. Shaft:
The shaft connects the impeller to the motor and transmits
rotational motion.
3. Casing:
The casing surrounds the impeller and directs the flow of fluid.
It typically has a simple cylindrical shape unlike the volute
shape found in centrifugal pumps.
4. Mechanical seal:
Prevent leakage between the rotating impeller and the
stationary casing.
5. Bearings:
Support the rotating shaft, reduce friction, resist thrust and
unintentional rotary movement.

14
Shaft assembly

Bearing

Propeller

Casing

15
Working mechanism
1. Fluid Intake:
The fluid enters the pump through the suction port.

2. Impeller Rotation:
The impeller rotates, driven by the motor.

3. Fluid Acceleration:
As the impeller rotates, its blades force the fluid to move axially. The
fluid's velocity increases due to the centrifugal force generated by the
impeller.

4. Pressure Increase:
As the liquid leaves the pump, its pressure increases. This is due to the
Bernoulli principle, which states that as the velocity of a fluid decrease,
its pressure increases.

5. Fluid Discharge: The high-pressure fluid is then discharged from the

pump through the discharge port.

16
 2. Positive displacement pumps
Positive displacement pumps are a type of pump that works by trapping a
fixed volume of fluid and forcing it out, combining rotation with displacement.
They're widely used across various industries due to their ability to deliver
precise and consistent flow rates, regardless of the viscosities being handled.

They are subdivided into two categories, each having its different types.

1. Rotary PD pumps including (Screw, Gear, Lobe and Vanes.)

2. Reciprocating PD pumps including (piston, plunger and diaphragm)

We shall discuss every type individually in the next section.

 Screw pumps
Rotary positive displacement pumps that use one or more screws to transport
a liquid along the axis of the screw.

Most of the components are familiar to us and similar to other pumps like the
motor, shaft, Seals, Bearings, Inlet and outlet ports, Yet the parts characterizing
a screw pump are the rotor, stator and the cavity between them.

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 Rotor:
This is the rotating element of the pump that contains the screw(s), the
screw(s) are machined with helical threads that create a pumping action.

 Stator:
The stator is the stationary part of the pump that surrounds the rotor
providing support for the rotor and forms the internal pumping chambers.

 Cavity:
 The space between the rotor and stator forms a series of cavities that
trap and transport the fluid. As the rotor rotates, these cavities
expand and contract, drawing fluid in and forcing it out.
 The tighter the gaps, the more velocity the liquid gains running
through them the more total head produced by the pump.
 The cavities tightness is limited to a range to avoid friction effects.

Rotor

18
 Multi screw pumps
The need for multiple-screw pumps rises when a large flow rate is handled, it’s
achieved by using two or three rotors and a larger stator containing them.

The rotor connected to the driving shaft is called the power rotor while the
other rotors are connected to the power rotor and called idler rotors.

A new component is installed to ensure smooth and synchronized movement

between the rotors, this component is called a timing gear.

The difference between the twin screw pump and the triple screw pump other
than capacity is that there is an allowance between the two rotors in the case of
the double screw while the three screws in the triple screw pump are touching
one another.

Idler

Power

Double screw pump

Idler

Power

Idler

Triple screw pump

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  Gear pumps
The most common type of Rotary positive displacement pumps, it uses
interlocking gears to move fluids similarly to screw pumps, one gear is a driving
(power) gear while the other one is a dependent (idle) gear.

Types of gear pumps:

 External gear pumps:

o Use two external parallel gears that mesh together conveying the
liquid around them not between them from suction to discharge.

 Internal gear pumps:

o Use one external gear and one internal gear that mesh together
conveying the liquid in the space between them from suction to
discharge.

o The internal gear is commonly the one connected to shaft so it’s

the power gear and the center of the inner gear is shifted
towards the inlet.

o A spacer is Installed between the two gears to seal suction and

discharge and tighten the gap giving more kinetic energy to the
fluid.

o A pressure relief valve is installed optionally to protect the pump

from excessive pressure.

20
  Lobe pumps
A Rotary positive displacement using two lobes to move fluids.

These lobes mesh together and rotate independently of each other without
touching, creating a series of cavities that trap and transport fluid.

A timing gear is crucial for a smooth and synchronized rotation disallowing

overlapping between the two lobes.

This type is associated with low pressure and high flow rates operations.

They are similar to gear pumps in terms of their positive displacement principle.
However, lobe pumps offer a smoother flow and reduced pulsation due to the
non-touching lobes.

21
  Vane pumps
A Rotary positive displacement pump rotating vanes to move fluid.

It consists of a rotor with vanes mounted radially on it, rotating inside a cavity.
The vanes maintain a close seal against the casing wall, creating a series of
chambers that trap and transport fluid.

The vanes could either be sliding rigid vanes or flexible ones

This type of pump is associated with low pressure service as they are designed
to operate at low vane velocity to avoid rubbing velocity caused by excessive
friction between the vanes and the pump casing.

22
  Reciprocating pumps
Reciprocating pumps are a type of positive displacement pumps that operate
by creating a reciprocating motion (back and forth movement) to displace a
liquid.

How Reciprocating Pumps Work

1. Intake Stroke:
a piston moves away from the discharge port, creating a vacuum. This
low pressure draws fluid into the pump chamber.

2. Discharge Stroke:
That piston moves towards the discharge port, compressing the fluid
and forcing it out of the pump.

According to the intake stroke, a vacuum is created, so priming is achieved

automatically.

That kind is associated with low flow rates and high pressure goal.

 Piston pumps
The simplest form of reciprocating pumps, it uses a reciprocating piston to move
fluid into the pump via suction check valve and out via discharge check valve.

23
  Plunger pumps
Similar to a classic piston pump but the displacer shape is a plunger similar to
plungers found in our homes, not a piston.

Comparison of Plunger and Piston Pumps

Feature Plunger Pump Piston Pump

Displacer Solid plunger Piston with rings or seals

Check valves Spring loaded Ball check valves

Fluid Flow Pulsating Smoother and more continuous

Efficiency Generally lower Generally higher

Viscosity Handling Excellent Good

Pressure Capability Very high High

the previous comparison makes the piston type more common in general

24
  Diaphragm pumps
a reciprocating positive displacement pump that uses a flexible diaphragm to
displace fluid.

utilizing two diaphragms working in a synchronized manner offers several

advantages over single diaphragm pumps including:

1-Synchronized Movement:
The two diaphragms move in opposite directions, creating a continuous flow
of fluid.

2- Fluid Transfer:
As one diaphragm moves downward, creating a vacuum, the other moves
upward, forcing fluid out. This ensures a consistent flow without pulsation.

3-Increased Flow Rates:

Double diaphragm pumps can often handle higher flow rates than single
diaphragm pumps.

4-Enhanced Self-Priming:
The double diaphragm design can improve self-priming capabilities, making it
easier to pump fluid from a low suction head.

The working process involves the following steps:

1. Intake Stroke:
Diaphragm Movement:
One diaphragm moves downward, creating a vacuum in the corresponding
fluid chamber.

Fluid Intake:
The low pressure draws fluid from the suction port into the fluid chamber.

2. Discharge Stroke:
Diaphragm Movement:
The other diaphragm moves upward, compressing the fluid in its chamber.

Fluid Discharge:
The increased pressure forces the fluid out of the discharge port.

25
key components
1. Diaphragms:
These are flexible membranes that separate the air chamber from the
fluid chamber. Their movement creates the pressure differential
required for pumping.

2. Air Chamber:
This chamber is filled with compressed air, which is used to actuate the
diaphragms.

3. Fluid Chamber:
This chamber holds the fluid to be pumped.

4. Suction and Discharge Ports:

These ports allow fluid to enter and exit the pump.

5. Check Valves:
These valves prevent backflow of fluid.
could be spring loaded or ball check valves.

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  P&ID Pump Symbols
The following section shows the most common P&id symbols related to pumps.

For more, you can refer to:

https://www.edrawsoft.com/pid/images/pid-legend.pdf
&
https://www.northridgepumps.com/article-221_what-are-pump-pid-symbols

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Problems & troubleshooting
 Vapor lock
Vapor Lock in pumps is a phenomenon that occurs when the liquid being
pumped becomes vaporized within the pump itself.
This vaporization can cause the pump to lose its prime, leading to reduced or
no flow.

Causes of Vapor Lock in Pumps

High Temperatures:
Elevated temperatures can cause the liquid to vaporize more readily.
Low Pressure:
Low suction pressures can contribute to vaporization, especially in liquids with
low boiling points.

Gas Entrainment:
Air or other gases in the liquid can reduce its density and lower its boiling point.
Poor priming:
Improperly primed or installed pumps can create conditions conducive to
vapor lock.

Prevention and Solutions

Temperature Control:
Insulate pipes and tanks to minimize heat gain by insulation, coating or pipe
burial.

Pressure Management:
Ensure adequate suction pressure to prevent vaporization (NPSHA).

Gas Removal:
Install a bleed valve to release any gases.

Ensure proper priming

Vent the pump to release trapped air.

Avoid air entrainment during negative suction

make sure that the intake gets enough liquid.

28
  Cavitation
it’s a phenomenon that occurs in
pumps when the liquid being
pumped gets vaporized due to low
pressure.
This vaporization creates bubbles
that collapse violently, causing
damage to the pump's internal
components.

 Effects of Cavitation
Noise and Vibration:
Cavitation causes a characteristic "hammering" sound and increased
vibration.
Reduced Efficiency:
Cavitation can significantly reduce the pump's efficiency.
Erosion:
The violent collapse of bubbles can cause erosion and pitting of the
pump's internal surfaces.
Pump Failure:
Severe cavitation can lead to premature pump failure.

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 Causes of cavitation

Operational causes:
operating under high temperature, low pressure and\or low flow rate are all
reasons that can cause vaporization of a proportion of the fluid pumped.

Frictional pressure drop:

friction along pipes causes pressure loss hence, a low NPSHa could be
encountered

Pump Design Flaws:

Inefficient pump designs or obstructions in the suction line can contribute to
cavitation.

Gas in the Liquid:

The presence of dissolved gases in the liquid can lower its vapor pressure,
making it more susceptible to cavitation.

 Prevention of cavitation

good priming:
good priming as previously discussed is crucial to avoiding cavitation.

Operating Conditions:
Monitor and control liquid temperature and flow rate to prevent cavitation

System Design:
Ensure adequate suction line sizing and avoid bends, elbows or pores that can
cause pressure losses or air entrance.
always make sure that the intake level is way below the tank liquid level to avoid
air entrance and low flow rates

Material selection:
choosing the right materials for pump parts while designing is very important
as some metals are more resistant to cavitation than others.

30
Pump performance curves.
A pump performance curve is a graphical representation that illustrates a
pump's efficiency and capacity at various operating points. It typically shows
the relationship between a pump's flow rate, its head and other parameters.

 Components of a Pump Performance Curve:

1. Flow Rate (Q):
This is the volume of fluid that the pump can deliver per unit time.

2. Head differential (H):

the difference between the discharge and suction heads given at
different impeller diameters, inversely proportional to the flow rate.

3. Efficiency (η):
This is the ratio of the output power to the input power. It indicates how
effectively the pump converts electrical energy into hydraulic energy.

4. NPSH (Net Positive Suction Head):

This is the minimum pressure required at the pump suction to prevent
troubles as mentioned before.

5. Horsepower:
These lines intersect the pump curve at the operating points where the
pump delivers that specific horsepower.

6. BEP (Best Efficiency Point):

refers to the operating point (combination of flow rate and head) where
a pump operates at its highest efficiency.

7. Recommended range:
Typically for a pump's operation is within ±10% of the BEP.

8. Shutoff Head:
This is the head a pump can produce at zero flow. It is the highest point
on the curve.

31
  Applications of Pump Performance Curves:
 Selecting the right pump: Curves help engineers choose pumps that
meet the specific requirements of a system in terms of flow rate, head,
and efficiency.

 System analysis: Curves can be used to analyze the performance of a

pump within a system, identifying potential bottlenecks or inefficiencies.

 Pump troubleshooting: Deviations from the expected performance

curve can indicate problems such as impeller damage, cavitation, or
excessive wear.

 Realistic pump curves

the previous curve is a simplified form of the pump characteristic curve, a more
detailed version is supplied by the designer company for customers to choose
a suitable pump according to their specific needs of flow rate and total head.

32
  Pump selection from curves
we use the flow rate and the total head to get the efficiency gained from each
presented pump option and choose the pump with the highest efficiency.

How to best choose a pump according to the performance curve:

1. Flow Rate:
Locate the required flow rate on the horizontal axis.
2. Head Pressure:
Find the corresponding head pressure on the vertical axis.
3. Intersection:
The point where these two values intersect on the pump curve
represents the pump's operating point.
4. Efficiency:
Check if the operating point is close to the BEP for optimal efficiency.
5. NPSH:
Ensure the pump's required NPSH is met under the given operating
conditions.

A practical example,
you were asked to choose a pump to operate 150 gallon per
minute with differential head 70 ft.liq from the national pump
company (providing an online open-source curves document)
curves are found in doc pages (123:261).

Classic graphical approach

for simplification purpose, we’ll only consider the first few curves.

Curve 1:
150 gpm is out of range, so we skip this pump.

33
 Curves 2,3:
point is out of range as follows:

Curves 4,5:
yield efficiency almost 71% and best impeller diameter above 4.845 inches as
follows (NOTED).

34
Curves 6,7:
yield efficiency almost 68% and best impeller diameter above 4.625 inches as
follows (NOTED).

Taking more and more curves into consideration gives more options but for
simplification, we’ll settle for the first few curves as mentioned and choose our
71% efficient pump from the fourth curve as our choice.

After locating the operating point on the curve (flow, head), refer to the NPSHr
curve and the power curve to get their values at your current flow rate.

 Another approach is to use Modern software tools that significantly

streamline the pump selection process.

These tools often include extensive databases of pumps, advanced analysis

features, system modeling capabilities, and energy efficiency calculations.
By using such software, you can efficiently select the most suitable pump
for your application, optimize system performance, and reduce energy
consumption.

35
Once you've selected a pump based on its characteristic curve, the curve can
provide additional valuable information:

1. Optimal Operating Point:

 Efficiency:
The curve helps you identify the flow rate and head pressure at which
the pump operates most efficiently.

 Best Efficiency Point (BEP):

Operating close to the BEP minimizes energy consumption and
maximizes performance.

2. Performance Limitations:

 Shutoff Head:
The maximum head pressure the pump can generate at zero flow.

 NPSH Requirements:
The curve indicates the minimum NPSH required to prevent troubles.

 Flow Rate Limits:

The curve shows the maximum flow rate the pump can deliver at a given
head pressure.

3. Performance Variations:

 Head Pressure Changes:

The curve illustrates how the head pressure varies with changes in flow
rate. This information is useful for understanding the pump's behavior
under different operating conditions.

 Efficiency Variations:
The curve can show how the pump's efficiency changes as the flow rate
and head pressure vary.

4. Troubleshooting:

 Performance Issues:
If a pump is not performing as expected, the characteristic curve can
help identify potential problems, such as operating outside the optimal
range or insufficient NPSH.

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