Pumping of Liquids

Most standard pump curves illustrate the effect of

changing impeiler diameters on characteristic performance (Figure 3-36A). Note change as reflected in the
different impeller diameters. However, the slight change
in efficiency is not irecorded over the allowable range of
impeller change.
Recognizing the flexibility of the affinity laws, it is better to select an original pump impeller diameter that is
somewhat larger than required for the range of anticipated performance, and then cut this diameter down after
in-service tests to a slightly smaller diameter. This new performance can be predicted in advance. Once the impeller
diameter is too small, it cannot be enlarged. The only
solution is to order the required large impeller from the
manufacturer.

Example 3-15: Reduicing Impeller Diameter at Fixed

M

If you have a non-cavitating (sufficient NPSH) operating %inch impeller producing 125 GPM at 85 feet total
head pumping kerosene of SpGr = 0.8 at 1750 rpm using
6.2 BHP (not motor nameplate), what diameter impeller
should be used to make a permanent change to 85 GPM
at 68 feet head, at the same speed?

Qz = Qi (dz/di)

203

When the performance of a pump handling water is

known, the following relations are used to determine the
performance with viscous liquids [ 171:

(3-34)

= CE(EW)

Determine the correction factors from Figure 3-56 and

Figure 3-57, which are based on water performance
because this is the basis of most manufacturers performance curves (except, note that the standard manufacturers performance curves of head us GPM reflect the
head of any fluid, water, or other non-viscous). Do not
extrapolate these curves!
Referring to Figure 3-56 [ 171:

1. The values are averaged from tests of conventional

single-stage pumps, 2-inch to %inch, with capacity at
best efficiency point of less than 100 GPM on water
performance.
2. Tests use petroleum oils.
3. The values are not exact for any specific pump.

(3-23)

85

125(dz/9)
dz = 6.1 in. diameter (new)

Referring to Figure 3-57 [ 171:

1. Tests were on smaller pumps, 1-inch and below.

The expected he:ad would be

2. The values are not exact for any specific pump.

(3-24)
H2 = HI (dz/di)
Hz= S5(6.1/9)n
= 39.0 ft (must check system new total head to determine if it will satisfy this condition.)

The expected brake horsepower would be

BHPB = B H P l ( d ~ / d 1 ) ~
BHPz = 6.2(6.1/9)3
= 1,93 BHP (use a 2- or 3-hp motor)

(3-25)

The charts are to be used on Newtonian liquids, but

not for gels, slurries, paperstock, or any other non-uniform liquids [ 171.
Figure 3-56 and 3-57 are used to correct the performance to a basis consistent with thie conditions of the
usual pump curves. In order to use the curves, the following conversions are handy:
Gentistokes = centipoise/SpGr

Eflects of Viscosity
en viscous liquids are handled in centrifugal pumps,
the brake horsepower is increased, the head is reduced,
and the capacity is reduced as compared to the performance with water. The corrections may be negligible for
viscosities in the same order of magnitude as water, but
become significant above 10 centistokes (10 centipoise for
SpGi- = 1.0) for heavy materials. While the calculation
methods are acceptably good, for exact performance
charts test must be run using the pump in the service.

SSU = Saybolt Seconds Universal

= (Centistokes) (4.620) at 100F
= (Centistokes) (4.629) at 130F
= (Centistokes) (4.652) at 210F

Example 3-16: Pump Performance Correction For

Viscous Liquid
a

When the required capacity and head are specified for

the equivalent capacity when pumping

~ ~ S C O Uliquid,
S

(text continued on page 206)

204

Applied Process Design for Chemical and Petrochemical Plants

Figure 3-56.Viscosity performance correction chart for centrifugal pumps. Note: do not extrapolate. For centrifugal pumps only, not for axial
or mixed flow. NPSH must be adequate. For Newtonianfluids only. For multistage pumps, use head per stage. (By permission, Hydraulic lnstitote Standards for Centrifugal, Rotaw, and Reciprocating Pumps, 13th ed., Hydraulic Institute, 1975.)

205

CAPACITY-GALLONS PER MINUTE (at bep)

Figure 3-57. Viscosity performance correction chart for small centrifugal pumps with capacity at best efficiency point of less than 100 GPM
(water performance). Note: Do not extrapolate. For small centrifugal pumps only, not for axial or mixed flow. NPSM must be adequate. For
Newtonian fluids only. For multistage pumps, use head per stage. (By permission, Hydraulic lnstitufe Standards for Centrifugal, Rotav, and
Reciprocating Pumps, 13th ed., Hydraulic Institute, 1975.)

Applied Process Design for Chemical and Petrochemical Plants

206

7. Calculate Brake Horsepower for viscous liquid

(text continuedfrom page 203)

water needs to be determined using Figure 3-56 or 3-57 in

order to rate pump selection from manufacturers curves.
(3- 35)

Determine proper pump selection and specifications

when pumping oil with SpGr of 0.9 and viscosity of 25 centipoise at the pumping temperature, if the pump must
deliver 125 GPM at 86 feet total head (calculated using
the viscous liquid).

Centistokes = 25/0.9 = 27.8

Referring to Figure 3-56:

1. Enter capacity at 125 GPM, follow vertically to 86

feet of head, then to right to viscosity of 27.8 centistokes, and up to correction factors:
Efficiency, CE = 0.80
Capacity, CQ = 0.99
Head, CH = 0.96 (for 1.0 QN),
QN= head at best efficiency point

4.3 E. horsepower

2. Calculate approximate water capacity:

(3-32)

QdCQ

Qw = 125/0.99 = 126.3

3. Calculate approximate water head:

89.6 ft

When a pump performance is defined for water, the

corrected performance for a viscous fluid can be developed using Figure 3-56 or 3-57. In order to develop the
curves for viscosity conditions of 100 SSU or 1,000 SSU as
shown in Figure 3-58, the following general procedure is
used [17].

1. Starting with performance curve based on pumping

water:
a. Read the water capacity and head at peak efficiency. This capacity is the value of (1.O
b. Using this value of GPM, calculate 0.6, 0.8 and 1.2
times this value, giving 0.6 QnW, 0.8 QnMT and 1.2
QnWrespectively, and read the corresponding
heads and water efficiencies.
2. Using Figure 3-56 or 3-57 enter GPM at value corresponding to peak efficiency, 1.0 Qnw,and follow up
to the corresponding head value, H, then move to
the viscosity value of the liquid, and up to the correction factors CE,CQ CH.
3. Repeat step 2 using GPM and head values of step
(Ib).
4.Correct head values:

a,).

Note this represents a flow rate using water under maximum efficiency conditions [ 171.

Hw = H~,/CH= 86/0.96

(86) (O)
(3960) (0.568)

Example 3-17: Corrected Performance Curves for

Viscosity Effect

Viscosity conversion:

QW

(3-33)

5. Correct efficiency values:

4. A pump may now be selected using water as the
equivalent fluid with capacity of 126.3 GPM and
head of 89.6 feet. The selection should be made at
or very near to the point (or region) of peak performance as shown on the manufacturers curves.
5. The pump described by the curves of Figure 3-36 fits
these requirements. The peak efficiency is 71 percent using water.
6. Calculate the viscous fluid pumping efficiency:
evis = C,(e,,J
= (0.80)(71) = 56.8%

(3-34)

e ~ =s ewCE

(3-34)

6. Correct capacity values:

%s

=a C Q

(3-32)

7. Calculate the viscous BHP as indicated in the previous example.

8. Plot values as generally indicated on Figure 3-58 and

obtain the performance curves corresponding to
the viscous liquid conditions.

Pumping of Liquids

/oo

200
180

90

L
Q)

207

80

160

7'0

140

*
2
50 .-r100
af
I L L

'z

20 :E 40
80
15 E 3 0 $60
af I O
20
40
.a?
b
0
I
20
in
0

100 200 300 400

Capacity Gpm.

500

Figure 3-58. Typical curves showing the effect on a pump designed for water when pumping viscous fluids. (By permission, Pic-a-Pump,
4 959, Allis-Chalmers Mfg. Co.)

or, alternate procedure [33,6]. For low capacity:

Temperature Rise md Minimum Flow

When a pump operates near shut-off (low flow) capacity alnd head, or is Iiandling a hol material at suction, it
may become overheated and create serious suction as well
as mechanical problems. TOavoid overheating due to low
flow, a minimum rate (GPM) should be recognized as
necessary for proper heat dissipation. However, it is not
necessarily impossible to operate at near shutoff conditions, provided (1) it does not operate long under these
conditions, as temperature rises per minute vary from less
than 1 "F to 30-4OoF, or (2) a by-pass is routed or recycled
from the discharge through a cooling arrangement and
back to suction to artificially keep a minimum safe flow
through the pump while actually withdrawing a quantity
below the minimum, yet keeping the flowing temperature
down [SI].

1. Temperature rise in average pump during operation

[GI.

ATr =

42.4 Ps,
~

w, c p

,')F/min [ 2 5 ]

where [25]
ATr

temperature rise, "F/min

P,, = brake horsepower at shutoff or no flow

Mil = weight of liquid in pump, Ibs
cp = specific heal of liquid in pump

(3- 36)

(3-37)

where H,,

total head of pump at no flow or shutoff or at any

flow rate with corresponding efficiency from
pump curve, ft

e = pump efficiency at the flow capacity involved (low

flow), decimal

Another alternate procedure [ 101

AT, = (GPM) (Hso)(SpGr)/3960

(3-38)

See Figure 3-59 and Figure 3-60 for a graphical solution

to the equation above for temperature rise. Figure 3-59
illustrates the characteristics of a boiler feed water pump
set to handle 500 GPM water at 220F for a total of 2600
feet head. The temperature rise curve has been superimposed on the performance chart for the pump, and values
of ATr are calculated for each flow-head relationship. Note
how rapidly the temperature rises at the lower flows. This
heating of the fluid at low flow or no flow (discharge valve
shut, no liquid flowing through the pump) can be quite
rapid and can cause major mechanical problems in the
pump's mechanical components. The maximum temperature rise recommended for any fluid is 15F (can be a bit
higher at times for the average process condition) except
when handling cold fluids or using a special pump
designed to handle hot fluid, such as a boiler feed water
pump of several manufacturers.

208

Applied Process Design for Chemical and Petrochemical Plants

600
700

600
w

500

b
8

400

m
w

300

2
%

200
100

Figure 3-59.Typical temperature rise for boiler feed water pump. (By permission, Transarnerica Delaval EngineeringHandbook,4th ec
Welch, ed., 1983, Transamerica Delaval, Inc., IMO Industries, Inc., Div.)

Temp. rise, 'F/min =

(BHP at shutoff) (42.4)
(weight of liquid in pump) (c )

( 3 - 36)

or

Temp. rise 'F/min =

(BHP - WHP) (2545)

(pump capacity )

(3 - 39)

2. Minimum Flow (Estimate) [6]

The validity of the method has not been completely
established, although it has been used rather widely in setting approximate values for proper operation [lo]. For
multistage pumps use only the head per stage in temperature limit by this method.
a. Determine NPSHA available at pump suction
b. Add the NPSH value to the vapor pressure of the
liquid at suction conditions. This represents the
vapor pressure corresponding to the temperature of
the liquid at the flash point. Read temperature, t2,
value from vapor pressure chart of liquid.
c. Allowable temperature rise = t2 - (actual pumping
temperature). Boiler feed water practice uses 15F
rise for average conditions [ 101.

200

300

500
l.000
2000 3,000
TOTAL HEAD, IN FEET

SPOO

Figure 3-60.Temperature rise in centrifugal pumps in terms of total

head and pump efficiency. (By permission, Karassik, I. and Carter,
R., Centrifugal Pumps, McGraw-Hill Book Co. Inc., 1960, p. 438.)

d. Approximate minimum safe continuous flow efficiency:

eEr1

Hsn,at shutoff from curve

778(AT, ) c p + H s n ,at shutoff

(3-40)

Pumping of Liquids

where

safe flowing efficiency, overall

plump, fraction

ehf = minimum

H,, = hiead at no flow oir shutoff, ft

cp = specific heat of liquid, BTU/lb/"F
AT, = temperature rise in liquid, "F

Example 3-18: niladmum Temperature Rise Using Boiler

Feed Water
Using the example of Reference [GI, assume a pump
with characteristic curve and added temperature rise data
as shown on Figure 3-59 is to handle boiler feed water at
2.2O0F, with a system available T\TPSHA = 18.8 feet. The
vapor pressure of water at 220F is 1'7.19 psia from steam
tables and the SpGr = 0.957. Correcting the 18.8 feet
NPSHA: psia = 18 8 (1/[2.31/0.957)] = 7.79 psia at

220T
The vapor pressure to which the water may rise before
ashes is 17.19 psia + 7.79 p i a = 24.98 psia.
From steam tables (or fluid vapor pressure tables),
read at 24.98 psia (for water of this example), temperature = 240F.
Therefore, allowable temperature rise of the water
(this example) = 240" - 220F = 20F.
A plotted curve as shown on Figure 3-59 [33] shows
that at point A a rise of 20F on the temperature rise
curve corresponds tlo a flow of 47 GPM minimum safe for
the pump handling 220"F, with NPSHAOC 18.8 feet.
An alternate estirnate for minimum flow [ 111:
Minimum flow (6or water) through pump,
(3-41)

0.3 PSO,GPM

where P,, = shutoff horsepower

For cold !iquids, general service can often handle ATr of
up to I O O T , a rule with approximately 20% factor of safety:
Qvl

(3-42)

6 P,,/AT,, GPM

ATr = permissible temperature rise,

fluid handled and the calculated NPSHA condition. For

NPSHRrefer to corrections discussed earlier.

Centrifugal Pump Specifications

e. Read minimum safe flow in GPM from pump performance curve at value of minimum efficiency calculated in (d).

Q M =

209

OF.

SHR required at the higher temperature may

become the controlling factor if cavitation is not to occur.
ow simply means that this flow must cirpump casing (not recirculate with no
cooling) back to at least the initial temperature of the feed,
atures are not to develop. The best pracmanufacturer to state this value for the

Figure 3-61 presents specifications for a centrifugal

pump. Although the process engineer cannot or should
not specify each item indicated, he must give the pertinent data to allow the pump manufacturer to select a
pump and then identify its features. Bumps are selected
for performance from the specific characteristic curves
covering the casing size and impeller style and diameter.
Often the process fluids are not well known to the pump
manufacturer, therefore the materials of construction, or
at least any limitations as to composition, must be specified by the engineer,

Example 3-19: Pump Specificationsns,

The pump specified identifies the design data, key portions of the construction materials and driver data as
required information for the pump manufacturer. If the
pump is to be inquiried to several manufacturers this is all
that is necessary. The individual manufacturers will identi@ their particular pump selection and details of construction materials and driver data. From this information
a pump can be selected with performance, materials of
construction, and driver requirements specified.
In the example the manufacturer has been specified
from available performance curves, and the details of
construction must be obtained. The pump is selected to
operate at 22 GPM and 196 to 200 feet head of fluid, and
must also perform at good efficiency at 18 GPM and a
head which has not been calculated, but which will be
close to 196 to 200 feet, say about 185 feet. Ordinarily, the
pump is rated as shown on the specification sheet. This
insures adequate capacity and head at conditions somewhat in excess of normal. In this case the design GPM was
determined by adding 10 percent to the capacity and
allowing for operation at 90 percent of the rated efficiency. Often this latter condition is not considered, although
factors of safety of 20 percent are not unusual. However,
the efficiency must be noted and the increase in horsepower recognized as factors which are mounted onto normal operating conditions.
Sometimes the speed of the pump is specified by the
purchaser. However, this should not be done unless there
is experience to indicate the value of this, such as packing
life, corrosion/erosion at high speeds, and suspended
particles; as the limitation on speed may prevent the manufacturer from selecting a smaller pump Hrn some cases it
must be recognized that high heads cannot be reached at
low speeds in single stage pumps. Table 3-7 presents sug-