Excerpt from Chapter 5, Pumps in: Hall, Stephen, Rules of Thumb for Chemical Engineers, Fifth Edition, ButterworthHeinemann,

2012. Available from the Amazon bookstore. System Curves This section illustrates how to create a system curve, using the example in Chapter 1. Then, pump characteristics and control valve settings are charted. The system consists of a feed tank, suction pipe, pump, discharge pipe, and destination tank. A system curve plots flow rate through the system (m3/h or gpm) against the pressure change through the pump (m or ft of fluid). Chapter 1 presented calculations for pressure drop due to pipe friction and fittings. The system curve adds liquid head (due to gravity). Data for the example are listed in Table 5-3. Line 215 is the pump suction pipe. The liquid level in the suction is 12 feet above the datum elevation. Line 216 is the discharge pipe; it discharges 23 feet above the datum elevation.
Table 5-3: The example is illustrated in Chapter 1, page Error! Bookmark not defined. Line Physical Length Contingency Subtotal Fittings Total Equiv L 215 216 4.5 m (14 ft) 26 m (85 ft) 1 m (3 ft) 5 m (15 ft) 5.5 m (17 ft) 30 m (100 ft) 3 m (10 ft) 15 m (50 ft) 8.5 m (27 ft) 45 m (150 ft)

The procedure for creating a system curve is as follows: 1. Use a spreadsheet to model the suction and discharge pipes. The primary input variable is flow rate. U.S units are used in the example. Start by listing all of the inputs needed to calculate the head pressures and pressure drop due to friction.
Figure 5-1: Input data for generating system curve

Excerpt from Chapter 5, Pumps in: Hall, Stephen, Rules of Thumb for Chemical Engineers, Fifth Edition, ButterworthHeinemann, 2012. Available from the Amazon bookstore. 2. Calculate the Reynolds Number, Friction Factor, and Pressure Drop due to friction in as described in Chapter 1. Also, obtain physical property data for vapor pressure, viscosity, and density based on the fluid temperature.
Figure 5-2: Pressure drop due to friction calculated with non-compressible flow equation and VBA function (see Chapter 1)

3. For the suction pipe, calculate the Net Suction Pressure by adding the pressure above the liquid (converted to units feet of fluid, described below) to the fluid pressure. Subtract the pressure loss due to friction, also converted to units feet of fluid. Formulas are: D48 D49 D50 = (D11+14.7)*2.31/(D37/62.4) = (D13-D14) = D28*2.31/(D37/62.4)

Where the second term, 2.31/(Dxx/62.4) corrects for the specific gravity of the fluid. There are 2.31 feet of water in 1 lb/in2. 4. For the discharge pipe, calculate the Net Discharge Pressure by summing the three terms (pressure at the discharge, elevation change, and pressure drop due to friction). Note that pressure drop is subtracted on the suction side, but added on the discharge side of the pump. 5. Next, calculate the Total Dynamic Head (TDH). Subtract the Net Suction Pressure from the Net Discharge Pressure.

Excerpt from Chapter 5, Pumps in: Hall, Stephen, Rules of Thumb for Chemical Engineers, Fifth Edition, ButterworthHeinemann, 2012. Available from the Amazon bookstore.
Figure 5-3: Calculate Total Dynamic Head in three steps

6. Create a table that relates flow rate to TDH. Substitute a range of values in the Flow Rate input cell (D16) and record the resultant TDH. Convert the flow rate to gallons per minute units. Use a scatter diagram to chart the system curve.
Figure 5-4: Convert flow rate to gpm (U.S. Units) before charting the system curve

Excerpt from Chapter 5, Pumps in: Hall, Stephen, Rules of Thumb for Chemical Engineers, Fifth Edition, ButterworthHeinemann, 2012. Available from the Amazon bookstore.
Figure 5-5: Completed system curve relates TDH (through the pump) to flow rate

Sensitivity Check the system curve for sensitivity to assumptions. Rules of thumb were used to estimate the equivalent length of the piping segments for the example problem. The fluid level in the feed tank affects the calculation for Net Suction Head. Vary the parameters and recalculate TDH. For the example, at 180,000 lb/h (about 360 gpm) the TDH ranges from 48 ft to 64 ft. The Base Case (above) computes to 58 ft so the variance is +10% to -17%. Operating Point and Pump Selection There are many factors to consider when selecting a pump. This section discusses hydraulic characteristics. Important hydraulic considerations include: Best Efficiency Point (BEP). Strive to select a pump that operates near its best efficiency. This minimizes energy consumption, and also decreases loads on the pump (from vibration, for instance) and maintenance requirements (Ref 12). Impeller size relative to pump housing. Centrifugal pumps usually accommodate a range of impeller sizes. Select a pump with an impeller that is smaller than the

Excerpt from Chapter 5, Pumps in: Hall, Stephen, Rules of Thumb for Chemical Engineers, Fifth Edition, ButterworthHeinemann, 2012. Available from the Amazon bookstore. maximum permissible; this provides contingency for increasing pumping capacity in the future. Speed. Pump wear increases with speed to seventh power (Ref 7). Slope of the operating line. When tight flow control is desired, the slope of the operating line is a factor in designing the flow control method

The example problem is used to illustrate these points. If it is stated that the flow rate should normally be controlled at a constant 360 gpm, and occasionally at 250 gpm, select a pump. Furthermore, assume that flow is controlled with a modulating valve. 1. Tentatively assign a pressure drop to the control valve. At 360 gpm, the TDH is 58 ft. Using the rule of thumb in Chapter 1, the control valve pressure drop should be 10% to 15% of the total, or 10 psi, whichever is greater. Since in this example the fluid is water, 10 psi = 23 ft fluid. This would give a controlled TDH of 58 + 23 = 81 ft. Checking, 23/81 = 28%. Therefore, a tentative pressure drop for the valve is 23 ft, and the normal operating point is 360 gpm at 81 ft TDH. 2. Use manufacturers published data to find pumps where the normal operating point falls near the BEP. Chart the System Curve and Pump Curves together as illustrated in Figure 5-6. The selected pump has a 10-inch impeller, trimmed to about 9.7 inches. When controlled at 360 gpm, the pressure drop through the control valve is about 20 ft to 30 ft, depending on how well the actual piping system adheres to the input assumptions. When controlled at 250 gpm, the pressure drop through the valve is about 60 ft.

Excerpt from Chapter 5, Pumps in: Hall, Stephen, Rules of Thumb for Chemical Engineers, Fifth Edition, ButterworthHeinemann, 2012. Available from the Amazon bookstore.
Figure 5-6: Chart system and pump curves together. Indicate the operating point (in this case with a diamond) and show the pressure drop taken by the control valve

3. Add the efficiency curves to the plot to confirm that the selected pump operates near its BEP. Figure 5-7 indicates an efficiency of about 68%.

Excerpt from Chapter 5, Pumps in: Hall, Stephen, Rules of Thumb for Chemical Engineers, Fifth Edition, ButterworthHeinemann, 2012. Available from the Amazon bookstore.
Figure 5-7: Efficiency curves

4. Pump curves may also indicate the power requirement (charted for water, specific gravity = 1). Select a motor that would not be overloaded if the pump operates at the extreme maximum flow rate, termed run out. In the example, this is at a flow rate of about 430 gpm. This could be achieved if, for instance, a branch line was installed between the pump discharge and the control valve, and the branch had a much lower pressure drop and static head than the primary discharge pipe. If the control valve is completely open, the operating point would be at about 410 gpm and 70 ft TDH. See Figure 5-8. 5. Pump curves also show the Net Positive Suction Head (NPSH) the pump requires and, often, the minimum recommended flow rate through the pump.

Excerpt from Chapter 5, Pumps in: Hall, Stephen, Rules of Thumb for Chemical Engineers, Fifth Edition, ButterworthHeinemann, 2012. Available from the Amazon bookstore.
Figure 5-8: Complete pump curve chart. The selected pump operates on the 9.7 in impeller line; the control valve absorbs the difference in head between the pump and the system curves.