The Impact of

Off-BEP Pump
Operation

Department Editor: Scott Jenkins

est-efficiency point (BEP), the flowrate
at which a pump operates at its
highest or optimum efficiency for
a specific impeller diameter, is a key
consideration when assessing pump
performance. While most pumps do not
consistently operate at their exact BEP, a
pump that is properly sized will maintain
a flow near peak efficiency (85105%
of BEP).
Operating a pump off-BEP means
that the flowrate is either too far above
or below the BEP for a sustained period
of time, resulting in a number of negative
consequences. This article outlines the
consequences of operating pumps away
from their BEP for extended periods, as
well as the key questions to ask when
assessing off-BEP pump operation.

Source: ITT Goulds Pumps

Consequences of off-BEP operation

Vibration and noise. Noise and vibration can occur when a pump operates
too far to the right of BEP, generating
high-velocity eddy currents that contribute
to the imbalance of pressure and shaft
deflection. The resulting stress on the
pumps internal components can lead to
poor pump performance, excessive wear
and increased risk of failure. The ideal
noise/vibration point is approximately
90% of BEP.
Cavitation. Cavitation occurs when
vapor bubbles continuously form and
collapse, creating intense pressure (up
to 10,000 psi) and shock waves (Figure
2). This is caused when the net positive
suction head required (NPSHR) increases
beyond the NPSH available (NPSHA),
or when the NPSHA drops below the
NPSHR. In determining reliability, if
the NPSHA in the system drops below
the NPSHR by the pump, the pump will
experience cavitation eroding the
impeller, vibrating the bearings and casings, and causing damage that can be
quite severe. The fatigued metal breaks
away, creating pitted surfaces, which
become concentration points for further
bubble collapse. NPSHR is typically
based on test standards established by
the Hydraulic Institute (www.pumps.org);
the definition of it is based on a 3% total

Venturi

Low velocity/
high pressure

Increased velocity /
pressure drop
Bubble
inception

Static pressure

Bubble
growth

Vapor pressure

FIGURE 2. Cavitation can be created for demonstration purposes using a venturi

head drop (Figure 1). At that 3% ratio,

a pump is already cavitating. That is
why there are common practices in the
industry that require a certain margin to
be in place to make sure a pump is not
running right at the NPSHA, and thus, by
definition, cavitating.
Bearing and seal failure. Bearing and
seal failure accounts for more than 80%
of all premature centrifugal pump failures, and occurs when a pump experiences increased radial and thrust loads
during off-BEP operation. Pumps that
have a single-volute casing design normally experience a rapid increase in impeller radial and thrust loads as the flow
declines below BEP flow. Dual-volute casing designs help to balance radial loads
and are essential for reliability when a
pump must operate for a substantial period of time at flows considerably below
its BEP flowrate. Modified concentric
volute-casing designs are an alternative
to single volutes offering reduced
radial loads in off-BEP operation, but
giving up a little bit of pump efficiency
in the process. The impeller loads that
develop during off-BEP operation can
lead to shaft deflection and mechanical
seal failures, or overload the bearings
with increased temperatures.
Discharge and suction recirculation.
Discharge and suction recirculation happens when fluid does not flow through
the pump as it was designed, causing
small flow instabilities called eddies. The
damage caused by eddies mirrors cavita-

Total head, ft

Source: ITT Goulds Pumps

Constant flow

3%
Of total head

14

12

10

Bubble
collapse

0
2
NPSHA, gage

10

FIGURE 1. Shown here is an example of an NPSH test plot used to determine a pumps NPSHR

tion and can lead to catastrophic pump

failure when portions of the impeller inlet
or discharge vanes fatigue and fail by
breaking off.
Temperature rise. Temperature rise is one
of the more severe effects of off-BEP operation, because at its most extreme, human
life can be lost. If a pump is allowed to
run at shut-off for an extended period
of time, enough energy can be applied
to the fluid to cause the pressure in the
pump to build to a point where its greater
than the yield strength of the casing, thus
causing an explosion. Such explosions
have been known to throw motors through
concrete block walls. The chances of this
happening are remote, yet real.
Key questions
The following application-related questions should be considered when assessing off-BEP pump operation:
What type of damage can occur if a
pump is run below the BEP?
What type of damage can occur if a
pump is run above the BEP?
How does off-BEP operation affect a
pumps mechanical seal?
Why does vibration increase in offBEP operation?
What are some ways pump manufacturers use hydraulic design to minimize loads on bearings and increase
bearing life?
Are proper operational controls in
place to prevent a catastrophic event?
In pursuit of peak efficiencies and
increased reliability (longer mean time
between failures), pump adjustments are
often made to align their BEP with the
duty point of the pumping systems. Consider testing a pump if you are uncertain
about its BEP for a specific application.
Editors note: Content for this edition of Facts at
your Fingertips was contributed by Rich Nardone,
global product manager at ITT Goulds Pumps (Seneca Falls, N.Y.; www.gouldspumps.com).