Part I: Optimizing Pumping Systems

PumpFundamentalsforanEnergyEfficientWorld
ByGreggRomanyshyn
The following is the first in a series of
articles based on select chapters from
thebookOptimizingPumpingSystems,
AGuidetoImprovedEnergyEfficiency,
Reliability, and Profitability, written by
pumpsystemsexpertsandpublishedby
Pump Systems Matter and the
HydraulicInstitute.
The U.S. Department of Energy has
determined that 25 percent of industrial
motor systems energy is currently
consumed by pumping systems.
Interest inenergy efficiency is not afad,
as industrial production economics,
global energy supply limitations, and
environmental conservation realities
figure to be an enduring theme for
decades, if not indefinitely.
As energy costs continue to increase,
pump manufacturers understand that
making equipment more efficient will
contribute to saving energy. While
traditional methods of specifying and
purchasing piping, valves, fittings,
pumps, and drivers often result in
lowest first cost, these methods often
produce systems with unnecessary,
expensive energy consumption and
higher maintenance costs. A business
entity that incorporates the energy,
reliability, and economic benefits of
optimized pumping systems can
enhance profits, gain production
efficiency improvement opportunities,
and initiate necessary capital upgrades
for long-termbusinesssurvival.
PumpFundamentals
The pumps used in pumping systems
fall into two general categories
rotodynamic (mixed flow, centrifugal
and axial flow) and positive
displacement.
Because the majority of pumps and
energy usage in industrial and
commercial applications are in the
rotodynamic pump category, this article
focuses exclusively on rotodynamic
pumps.
HowaRotodynamicPumpWorks
A rotodynamic pump converts kinetic
energy to potential or pressure energy.
The pumping units energy conversion
components havethreemajor parts: the
driver that turns the rotating element;
the impeller and shaft (the rotating
element); and the stationary diffusing
element.
Typically connected to the pumps
rotating element by a coupling, the
driver provides the energy to rotate the
shaft and impeller. With the pump
casing and the intake system primed,
the liquid enters the rotating impeller
eye, located along the axis of the
impeller. The liquid is accelerated into
the impellers vaned passageways,
where the continuous transfer of
momentum and energy conversion
occurs. As liquid flows through the
impeller passageways, velocity
increases.
When the liquid leaves the impeller,
liquidvelocity is greatest at thetipof the
vanes. The rapidly moving liquid leaves
the pump impeller, and then enters the
diffusing element of the pump. An
increase in cross-sectional area of the
flow passage occurs and the liquid
slows down. The deceleration of the
liquid in the diffusing section converts
the kinetic energy of the liquid to
potential or pressure energy. The
diffusing section of the pump can be
either a diffuser or a volute depending
onthepumpsconfiguration.
The shape, size, speed, and design of
the impeller and diffusing section
establish the pumps head and flow
characteristics. The pump impeller and
diffusing section designs are based on
the intended application, the users
specifications for the pump, and the
pump manufacturers experience. Once
a pump is selected, the casing design
envelope cannot readily be changed,
but theuser canoftenchangethepump
impeller diameter and/or adjust the
speed to better meet pumping
requirements. For certain pumps, the
manufacturer may have an alternate
impeller, designed for a higher or lower
capacity.
PumpSelectionConsiderations
Selecting a rotodynamic pump requires
careful analysis of the system head
versus flow requirements; the pump
performance characteristics; the pump
application; the footprint available for
the pump and driver; applicable
specifications, codes, regulations and
reliability; maintainability and energy
cost considerations. The specifying
engineer may need to work closely with
the pump manufacturer or distributor to
select the optimal pump and its size,
speed and power requirements, type of
drive, mechanical seal, and ancillary
equipment.
Understanding the Pump
PerformanceCurve
All pump selections must include
matching the operating characteristics
of the pump with the system
requirements over the expected range
of flows.
Continued..
By Dead Cat
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By Dead Cat
Types of Curves: There are three
basic types of pump curves supplied by
the pump manufacturer: the selection
chart (also known as the range chart or
the family of curves), the published
curveandthecertifiedcurve.
Selection Chart: A selection chart
shows the performance map for a
similar pump family. Figure 1 shows a
selection chart for a line of general-
purpose end suction pumps. The head
and flow scales on the hydraulic
coverage range chart are often
formatted on semi-log or log-log scales
to display a wider range of flow and
headvaluesonasinglechart.
The selection chart shows the various
pump sizes available for a given
manufacturers pump type and speed.
The required head and flowrates are
plotted on the curve, and the
manufacturer evaluates the pumps with
abest efficiency point near thespecified
operatingpoints.
The selection chart is useful in
developing a shortlist of pumps for
consideration. For example, if you were
lookingfor apumprunningat anominal
1,800RPMthat coulddevelop 100ft. of
headat 1,000GPM; fromFigure1it can
be seen that the 5x6x11, 5x6x13.5,
6x8x11, 6x8x13.5, and possibly the
8x10x13.5 size pumps overlap on the
selectionchart.
Published Curves: Once a shortlist of
acceptable pumps is developed, the
manufacturers publishedcurves canbe
referenced to help determine the best
pump for the application. Figure 2 is an
example of a published curve for a
5x6x11pumprunningat 1,770RPM.
Useful operating information can be
derived from the manufacturers pump
curve for this application, including the
following:
The impeller diameter falls between
10in. and10.5in.
The pump is 85 percent efficient at
thedesignpoint.
Thepumprequires approximately 30
hpat theoperatingpoint.
The net positive suction head
required is approximately 10 ft.
Contacting the pump manufacturer or
sales office to reviewthe suitability of a
given pump model for the specified
service conditions is recommended
whenspecifyingapump.
CertifiedCurve: After a pump has been
ordered and released for construction,
the manufacturer builds it, and if testing
is specified, the pump is tested and a
certified performance curve is supplied.
For reliable, consistent test results, it is
recommended that the test be
conducted in accordance with the
requirements of ANSI/HI 1.6 or 2.6.
Unlike the published curve, which is a
general curve for a given pump model
typeandsize, thecertifiedcurvereflects
the actual test results for the specific
pumpsuppliedfor thepurchaseorder
Optimizingpumpingsystems
PumpSuctionIntakeConsiderations
Pump Location in the System: The
pumps location in the system has a
major effect on the net positive suction
head available (NPSHA). A change in
the elevation of the pump or suction
source directly corresponds to an
increase or a decrease in the NPSHA.
In a new system, placing the pump at
the lowest possible point or elevating
the suction source can often be
accomplished with minimal cost impact.
After the systemis built, increasing the
NPSHAexcept for changinglevel set
pointsisoftencost-prohibitive.
Pump Suction Piping: The head loss
component of the NPSHA is based on
the friction losses in the pump suction
piping. These losses can be significant
and increase with the square of the
increasedratioof therateof flow. Pump
performance can be limited by the
NPSHA. Reducing the piping friction
losses may be possible by increasing
the diameter of the suction piping,
reducing the number of elbows or
fittings, or selecting valves with lower
losses, i.e., by replacing a globe valve
withagatevalve.
Liquid Properties: The temperature-
dependent properties of the process
liquid can significantly affect NPSHA,
head, rate of flow and power
requirements. Water at 68 F has a
vapor pressure head of 0.78 ft., but has
avapor pressureheadof 33.9ft. at 203
F. The increased water temperature
represents a 33 ft. reduction in NPSHa,
if no other changes are made. Changes
in liquid temperature affect the liquid
viscosity. For Newtonian liquids, raising
the temperature tends to reduce
viscosity, and lowering the temperature
tendstoincreaseviscosity.
Supply Tank and Atmospheric
Pressure: The pressure acting on the
liquid surface of a supply tank directly
affects the NPSHA. It may be possible
to increase the NPSHa by increasing
the suction tank pressure, but this
option shall not be selected without
verifyingthesupply tank pressurerating
andrelatedprocessfactors.
Pump Affinity Rules: The pump affinity
rules describe how changing the
impeller diameter (up to 5 percent
changeonly) androtational speedaffect
pump performance. The pump curve is
derived from a series of test points
connected together forming a smooth
line. The discrete flow and head test
values can be thought of as belonging
to a coordinate point. When using the
pump Affinity Rules, it is important to
adjust boththeheadandflowvalues for
thesamecoordinatepoint.
ChangesinRotational Speed: Whenthe
rotational speed of a pump is changed,
the rate of flow (capacity), head, and
power for a point on the pump curve
vary according to the pump Affinity
Rules.
FlowQ
2
=Q
1
x[N
2
/ N
1
]
HeadH
2
=H
1
x[N
2
/ N
1
]
2
PowerP
2
=P
1
x[N
2
/ N
1
]
3
Where:
Q=rateof flow
H=head
P=power
N=speed
subscript1indicatesexistingvalue
subscript2indicateschangedvalue
Optimizingpumpingsystems
Continued..
By Dead Cat
By Dead Cat
Figure 3 shows a pump performance
curve at the manufacturers test speed
of 1,770 RPM and a speed of 1,500
RPM. As the speed is reduced, the
pump curve moves down and shifts to
theleft.
The pump affinity rules do not
recommend what should be done to the
pump efficiency at the new speed.
However, pump efficiency usually
follows with the affinity rule adjustment
of flow.
The values of efficiency do not typically
change much with modest speed
changes.
The pump affinity rules provide an
accurate representation of pump
performance change over a range of
speeds.
Changes in Impeller Diameter: When
the diameter of a pump impeller is
trimmed (up to 5 percent change only),
the rate of flow, head, and power for a
point on the pump curve vary
approximately with the pump affinity
rules.
FlowQ
2
=Q
1
x[D
2
/ D
1
]
HeadH
2
=H
1
x[D
2
/ D
1
]
2
PowerP
2
=P
1
x[D
2
/ D
1
]
3
Where:
Q=rateof flow
H=head
P=power
D=impeller diameter
subscript1indicatesexistingvalue
subscript2indicateschangedvalue
Pump Operation: A pump must be
operated using established procedures
to minimize repairs and unexpected
downtime. A checklist should be
developed to verify that all safety
precautions, ancillary equipment and
valve settings, manufacturer
recommendations, instrumentation
hook-ups, etc. are in order before
startingapump.
When shutting down the pump it is
important to follow an established
shutdown sequence for safety and to
prevent hydraulic transient flow-related
problems, water hammer, reverse
rotation of the pump, unexpected
tripping of other equipment in the
system and other problems.
Gregg Romanyshyn is the technical
director attheHydraulicInstitute. Inthis
position, he oversees the technical
aspects related to the Hydraulic
Institute. Mr. Romanyshynhas over 30
years experience involved with pump
relatedbusinesses andhas beenat the
Hydraulic Institute for 10 years The
Hydraulic Institute is the largest
association of pump industry
manufacturers in North America and
serves the pump community by
providingproduct standards, guidelines,
andreferences, andis a forumfor the
exchangeofindustryinformation.
www.pumps.org
Optimizingpumpingsystems