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-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

A pump must overcome

the resistance of a
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)

Head
Pump
Resistance

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

Suction
Head
HS

Discharge
Head
HD

Static Head=HD - 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)

Static
Head

Discharge
Head
HD

Suction
Lift LS

Pump
Centerline
Static Head=HD + 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)

180
FT

160
FT

20
FT

Pump
Centerline
Static Head=
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

GPM
10
20
30
40
45
70
100

1"
Ft.

PSI

6.9
25.1
54.6
95.0

3.0
10.8
23.5
40.9

1.25"
Ft. PSI

1.50"
Ft. PSI

2"
Ft. PSI

1.8
6.3
13.6
23.5
30.7
68.8

0.8
2.9
6.3
10.8
13.5
31.3
62.2

0.3
0.9
1.8
3.1
3.9
8.9
17.4

0.8
2.7
5.6
10.1
13.2
29.6

0.4
1.3
2.7
4.6
5.8
13.5
26.8

0.1
0.4
0.8
1.3
1.7
3.8
7.5

Friction Head Loss

Every component of a pumping system has associated
friction losses
Equivalent length

Flow meters

PSI

20

15
10
5
GPM

25

100

175

TYPE
90
Elbow
Gate
valve
Globe
valve
Swing
check

1
1.6

2
3.1

3
4.4

4
5.9

1.2

2.6

2.8

2.9

45

70

94

120

7.2

17

27

38

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
Pump
20

20
2 Pipe

Nozzle
9.2 reqd
18

Static Head
2

Suction Lift
In this example the friction loss calculation is:

Equivalent length of fittings:

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

15

Pump

Suction Head

20

Nozzle
9.2 reqd

18
20

20
2 Pipe

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
Pump

20

20

2 Pipe

18

Static Head
2

Suction Lift

Nozzle
9.2 reqd

In this example the total dynamic head is equal to:

8

Static head = 24
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

15

Pump

Suction Head

20

18
20

20
2 Pipe

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

Nozzle
9.2 reqd

Head vs. Pressure

Because..
.

A given pump will

generate the same
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

2.31

Multiply water Hp x SG to get actual Hp

Feet of Head = PSI x 2.31

SG

>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 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.

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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

cause reduction in head
generation, or loss of prime.

* Bubbles collapsing create

intense pressures and
(10,000 psi) shock waves.
* Intense pressures near metal
surfaces exceed material
strength and fatigue metals.

* Large vapor volumes can

cause surging and unstable flows.

* Creates pitted surfaces.

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)

Problem Eliminated By Throttling

Increase NPSHa

Loss of Pressure\Flow

Pitted Impellers
Verification

Cures

Pressure\Power Triangulation

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
Pressures At The Proper
Temperature
Use The Minimum Liquid Height
Above The Pump Suction!

PV
HS

HF

NPSHA
Example A
Flooded Suction - Ambient Temp. - Sea Level

PB = 14.7
PSIA

HS =
15 FT

60 O F
VP=?

HF = 5

NPSHA = PB + HS - HF - PV
= 34 FT + 15 FT - 5 FT - 1.0 FT
= 43.0 FT

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

PB = 12.0 PSIA

200 O F
VP=?
HS =
15 FT

HF = 5 FT

NPSHA = PB + HS - HF - PV
= 27.6 FT + 15 FT - 5 FT - 27.6 FT
= 10.0 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

100 F
VP=?
O

HS =
6 FT

HF = 1 FT

= 2.3 FT + 6 FT - 1 FT - 2.2 FT
= 5.1 FT

THANK YOU!