Pump-Flo Method of Solution
Pump-Flo Method of Solution
Definitions
The definitions that follow are found in Reference 1 and are used in this section
for the discussion of PUMP-FLO’s solution method.
Head The quantity used to express a form (or combination of forms) of the
energy content of the liquid, per unit weight of the liquid, referred to any
arbitrary datum. All head quantities are in terms of foot-pounds of energy per
pound of liquid, or feet of liquid.
Flow The unit of flow rate in the United States is expressed in units of gallons
per minute (gpm). The standard fluid for all pump curves is water at 60 °F.
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NPSH The net positive suction head is the total suction head in feet of liquid
(absolute) determined at the suction nozzle and the referred datum less the
vapor pressure of the liquid in feet (absolute). NPSHa is the net positive
suction head available in the pumping system. NPSHr is the net positive
suction head required by the pump.
Pump Input The horsepower delivered to the pump shaft (designated as brake
horsepower).
Pump Efficiency The ratio of the energy delivered by the pump to the energy
supplied to the pump shaft (the ratio of the liquid horsepower to the brake
horsepower).
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Pump Limits
Max temperature: The maximum operating temperature is compared to the
maximum temperature specified in the catalog by the manufacturer. If the
maximum temperature value exceeds the catalog value, a warning flag is
issued.
Max suction pressure: The maximum pressure at the pump suction is added
to the shutoff dP and then this sum is compared to the maximum pressure
specified in the catalog by the manufacturer. If the maximum suction pressure
plus the shutoff dP is greater than the catalog maximum pressure, a warning
flag is issued.
Max sphere size: The largest particle size in the fluid is compared to the
maximum sphere size specified in the catalog by the manufacturer. If the
maximum sphere size exceeds the catalog value, a warning flag is issued.
Max power: The maximum power for the pump assembly or magnetic drive is
compared to the power limit specified in the catalog by the manufacturer. If the
maximum power exceeds the catalog value, a warning flag is issued.
Max suction specific speed (Nss): The maximum suction specific speed is
compared to the suction specific speed specified in the catalog by the
manufacturer. If the catalog value exceeds the maximum suction specific
speed, a warning flag is issued.
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Curve Limits
Minimum trim: The design curve diameter, expressed as a percentage of the
pump’s maximum impeller diameter. If the selected design curve diameter is
greater than this value, a warning flag is issued.
Min head rise: The minimum head rise from the design point to shutoff,
expressed as a percentage from the design point head to the shutoff head. If a
pump’s head rise from design point to shutoff is less than this value, a warning
flag is issued.
Pump Sizing
Each pump in the catalog can have up to ten impeller diameters or speed
curves. Each curve can have up to twenty data points describing the pump
operation. The data points for the curve consist of the flow rate and head, and
optionally the pump’s efficiency (or power) and NPSHr.
When the design point of the pump falls between a set of known curves, the
program interpolates between them to arrive at a calculated curve. Often
manufacturers allow impeller diameters to be adjusted only in fixed increments
of their choosing. For example, a manufacturer can force the program to limit
the impeller diameter increments to 0.125 inch. Or, they may not allow any
trimming of the impellers.
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(H1/H0) = (N1/N0)2(D1/D0)2
equation 1b
(P1/P0) = (N1/N0)3(D1/D0)3
equation 1c
Q = Capacity in gpm
N = Impeller speed in rpm
D = Impeller diameter
H = Pump head in feet
P = Pump power in hp
Subscripts
0 = Pump test speed or diameter
1 = New pump speed or diameter
Multi-stage Pumps
Pumps which have multiple impeller stages are designated as multi-stage
pumps. For these pump types, the single stage base impeller curves and the
impeller trim increment are specified in the manufacturer’s catalog along with
the range of allowed impeller combinations.
During the pump selection process, PUMP-FLO determines the number of full
diameter impeller stages necessary to achieve the design point. Once the
number of stages has been determined, the program calculates the impeller
diameter needed to go through the design point.
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The NPSH available can be entered directly or calculated using the NPSHa
Calculator.
Pt
Suction Piping
Z
Figure 1
The formula used to calculate the NPSHa is as follows (refer to Figure 1
above):
NPSHa = ((Pt - Pvp)/ρ) + Z – HL
equation 2
Pt = absolute pressure on the free
surface of the liquid in the tank
connected to the pump suction
Pvp = pumping fluid vapor pressure in
absolute pressure units at the
operating temperature
ρ = fluid density
Z = static suction head (this value is
negative if a suction lift condition
exists)
HL = head loss due to friction in the
pipeline between the tank and the
pump suction.
The units of NPSH are in feet of fluid absolute.
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An NPSH margin ratio can also be specified. This factor is applied to the
pump’s NPSHr value. PUMP-FLO checks that the NPSHa is greater than the
pump’s NPSHr multiplied by the margin ratio. If it is not, a warning flag is
issued.
The NPSHr for a pump is determined by the pump manufacturer and is listed in
their catalog. The NPSHr values are arrived at through actual tests as outlined
in Reference 1.
If the fluid is a hydrocarbon, or high temperature water, then the required NPSH
of the pump may be reduced as outlined in Reference 1. Using the NPSH
Reductions for Pumps Handling Hydrocarbon Liquids and High Temperature
Water chart found in Reference 1, it is possible to reduce the NPSHr values
specified by the vendor without causing cavitation.
The PUMP-FLO program does not perform the NPSH reduction calculations. If
based on your experience you can reduce the NPSH requirements of the
pump, the reduction value should be subtracted from the value presented by
PUMP-FLO. Always check with your pump supplier when adjusting the NPSH
requirements.
Submersible
Recirculating
Figure 2
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The formulas used to calculate the total head are listed below.
Flooded Suction and Suction Lift
Total head = ((Pd - Ps)/ρ) + (Zd - Zs) + HLs + HLd
Equation 3a
Pd = discharge tank surface pressure
Ps = suction tank surface pressure
Zd = static discharge head
Zs = static suction head (this value is
negative if a suction lift condition
exists)
HLs = head loss in the suction piping,
including valve/fitting losses
HLd = head loss in the discharge piping,
including valve/fitting losses
ρ = fluid density
Submersible
Total head = ((Pd - Ps)/ρ) + (Zd - Zs) + HLd
Equation 3b
Pd = discharge tank surface pressure
Ps = suction tank surface pressure
Zd = static discharge head
Zs = suction tank liquid level
HLd = head loss in the discharge piping,
including valve/fitting losses
ρ = fluid density
Submersible
Total head = HLr + HLs + Load1 + Load2
Equation 3c
HLr = head loss in the return piping,
including valve/fitting losses
HLs = head loss in the supply piping,
including valve/fitting losses
Load1 = return side load
Load2 = supply side load
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A list of typical valves/fittings is provided for both the suction and discharge
piping. The table below lists the valve/fitting coefficients (obtained from
Reference 4):
Valve/Fitting L/D coefficient or K value
Entrance K = 0.78
Exit K=1
90° Elbow L/D = 30
Ball valve L/D = 3
Butterfly valve 2" (50 mm) to 8" (400 mm), L/D = 45
10" (250 mm) to 14" (350 mm), L/D = 35
16" (400 mm) to 24" (600 mm), L/D = 25
Gate valve L/D = 8
Globe valve L/D = 340
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Temperature Variations
Variations in the temperature of the fluid being pumped cause changes in the
fluid density. Any reduction in the fluid density results in a reduction of the
liquid horsepower, along with a proportional reduction to the input power. As a
result, there is little or no change in the pump’s efficiency.
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The correction values shown in Figure 71 are averaged from tests that utilized
pumps with impeller sizes of 1 inch and below. This chart is used when the
flow rate at best efficiency is less than 100 gpm. The correction values shown
in Figure 72 are averaged from tests that utilized pumps with impeller sizes
ranging from 2 to 8 inches. This chart is used when the flow rate at best
efficiency is greater than 100 gpm. Reference 1 cautions the user not to
extrapolate outside the range of the published curves. The correction factors
are based on purely empirical data and if it is important to have accurate pump
data for the working fluid, the pump should be tested under the expected
operating conditions.
The reason PUMP-FLO employs correction factors for pumping viscous fluids
is that they are universally accepted by both pump vendors and users alike.
When the fluid being pumped has a viscosity of 4.3 centistokes or greater,
PUMP-FLO automatically performs the corrections to the pump performance
data found in the pump catalog. PUMP-FLO determines which correction
factors to use for each pump from the flow rate at the best efficiency point
(BEP) of the highest impeller diameter curve. If the BEP flow rate is less than
100 gpm, the correction factors corresponding to Figure 71 are used. If the
BEP flow rate is greater than 100 gpm, the correction factors corresponding to
Figure 72 are used.
Since there are no formulas available for the viscosity correction factors
presented in Reference 1, the PUMP-FLO program uses a set of equations
that are derived from the nomographs (Figures 71 and 72) to calculate the
factors. These correction factors are a function of the pump capacity, the head
of the first stage impeller, and the viscosity of the pumping fluid. Using the
basic equation shown below (Equation 4), a correction coefficient designated
as CC is produced. The slopes of the lines in the nomograph provide the
exponents for the variables in this equation. This correction coefficient is used
in equations 5, 6, 7, 8, 9, and 9a through 9d for the capacity, efficiency, and
head correction factors. A CC correction coefficient is calculated for each
impeller trim using its BEP flow rate and head. For example, a pump with ten
impeller trims would have ten different CC correction coefficients and thus 10
sets of correction factors, one for each impeller trim.
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The equations are bounded in the program to ensure that they are not
extended outside the viscosity, head, and flow rate ranges specified in
Reference 1. The equation bounds are shown below. If a pump has impeller
trims which are outside of the equation bounds, the performance data for the
pump is still corrected using the equations, but it is noted in the Graph
Window and on the data sheet report that the pump is out of range.
ν = µ * 62.424 /ρ
equation 4a
ν = viscosity in centistokes
H = head in feet of fluid
Q = flow rate in gal/min
µ = viscosity in centipoise
ρ = fluid density
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Efficiency
CE = 1.079527 - 3.413289E-02*CC - 2.747891E-04*CC2 +
1.927002E-05*CC3 - 1.649636E-07*CC4
equation 6
Bounds of CE 0.03 < CE < 1
Head
CH = 0.9724525 + 8.957773E-03*CC
- 6.784939E-04*CC2 + 1.085695E-05*CC3
- 5.587139E-08*CC4
equation 7
Bounds of CH 0.67 < CH < 1
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Head
Head corrections factors are calculated at 60, 80, 100, and 120 percent of the
best efficiency point flow rate. For flow rates at other percentages, PUMP-FLO
interpolates between these calculated correction factors.
CH.6 = 1.003993 - 1.927655E-03*CC
- 9.839067E-05*CC2 - 1.012695E-06*CC3
equation 10a
Bounds of CH.6 0.78 < CH.6 < 1
CH.8 = 1.004737 - 2.562881E-03*CC - 2.03951E-04*CC2 +
2.132138E-06*CC3
equation 10b
Bounds of CH.8 0.72 < CH.8 < 1
CH1.0 = 1.011042 - 5.992841E-03*CC
- 1.053868E-04*CC2 + 9.923402E-07*CC3
equation 10c
Bounds of CH1.0 0.68 < CH1.0 < 1
CH1.2 = 1.010846 - 9.467801E-03*CC
+ 1.715598E-05*CC2 - 7.677713E-07*CC3
equation 10d
Bounds of CH1.2 0.63 < CH1.2 < 1
If, during the calculations, any of the coefficients are outside of the bounded
values, the limits are used for the correction factors.
The coefficients for the correction curves were calculated using 33 data points
from Figure 71 and 30 data points from Figure 72. These data points were
used in a regression analysis to develop the formulas. All coefficients were
calculated using the nth order regression program outlined in Reference 3.
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Motor Sizing
Motor size tables used by PUMP-FLO can contain up to four different
standards. Each standard can have a maximum of four enclosure types. For
each standard and enclosure type, the table contains speed, frame, and motor
efficiency data.
When specifying the standard and enclosure type to use, the user also
specifies the sizing criteria. There are three different criteria available: the
power required at the design point flow rate, the maximum power required on
the design curve, and the maximum power required for the maximum impeller
diameter. The user can also specify an uncertainty factor. PUMP-FLO
multiplies the pump’s horsepower by the uncertainty factor and uses this value
when selecting the motor size.
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Operating Cost
The operating cost is the cost of the power required to run a pump for one year.
PUMP-FLO can calculate the annual operating cost for pumps running under
both fixed and variable speed conditions. This cost information provides
another parameter for consideration when comparing the advantages of using
one pump over another. It also provides useful information for determining if the
cost savings associated with operating a variable speed pump justifies the cost
of the variable speed drive.
PUMP-FLO uses information from the operating load profile and the
manufacturer’s pump curve to calculate the operating cost. If the cost is being
calculated for a variable speed drive pump, the resistance curve information is
used as well. The pump and motor efficiencies are also factored into the
calculation.
For a fixed speed pump, the sequence outlined below is followed for each load
specified in the operating load profile.
The brake horsepower is calculated:
bhp = Q*TH* ρ /(247,000 * effp)
equation 11
bhp = brake horsepower
Q = flow rate in gallons per minute
TH = total head in feet
ρ = fluid density in lb/ft3
effp = pump efficiency
The electrical horsepower is calculated:
ehp = bhp / effm
equation 12
ehp = motor electrical horsepower
effm = motor efficiency
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Figure 3
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Performance Curves
A typical AODD pump performance curve is shown below in Figure 4.
Figure 4
The pump performance (head vs. flow) is plotted for a series of air supply
pressures. Air consumption curves are overlaid on the head curves in either an
iso or line format. These curves indicate the air supply volume needed to
provide the required flow rate at a given discharge head.
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Fluid Compatibility
Each AODD catalog must have a corresponding Fluids Compatibility Table
(FCT file). The FCT file contains a list of fluids and fluid properties, along with
casing and diaphragm material compatibility ratings for the fluid.
For each fluid and material combination, the manufacturer can assign a code
which indicates the fluid/material compatibility. PUMP-FLO appends this code
to the front of the material name. If a code has not been specified for a
particular fluid/material combination, a “?” is appended to the material name,
indicating that the compatibility is unknown.
Viscosity Corrections
For high viscosity fluids, a flow capacity correction factor is applied to the
pump performance.
A graph of available pump capacity (expressed as a percentage) vs. fluid
viscosity (cP) is provided in Reference 5. Figure 5 below is a plot of data
obtained from that graph.
Figure 5
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References
1 Hydraulic Institute Standards for Centrifugal, Rotary & Reciprocating
Pumps, 14th edition, Hydraulic Institute, 1983.
2 Pump Handbook, Igor J. Karassik, William C. Krutzsch, Warren H. Fraser,
and Joseph P. Messina, editors; McGraw-Hill, Inc., 1976.
3 Science and Engineering Programs, edited by John Heilborn, McGraw-Hill,
Inc., 1981.
4 Crane, Crane Technical Paper 410, “Flow of Fluids through Valves, Fittings,
and Pipe” twenty fourth printing, Crane Company 1988.
5 Engineering Handbook AODD Pumps, Yamada America, Inc.
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