Analyzing centrifugal-pump circuits How do you estimate the flow in a given pump circuit, or select a pump for a given flow? This article provides an analytical estimation method for seven types of circuits. CF The actual performance of a centrifugal pump in a pipe circuit is determined by its characteristic head-vs.- capacity curve and the circuit's resistance-vs.flow curve. Where the curves meet is the operating point. If the ‘curves are expressed mathematically, then the operating point is obtained by solving the head-vs.-capacity and re- sistance-vs.-low equations simultaneously. ‘The graphical and mathematical approaches are both simple, as long as there is only one pump and a simple pipe circuit. But the graphical approach becomes un- wiclly when the circuit is complicated by branches, drawofls, and differing elevations. The other approach also gets complicated, but less so, and a mathematical so- ution can be programmed. ‘This article offers a mathematical approach to estimat- ing flow and head for a given pump, and seven different types of pipe circuits: series resistance; parallel resist- ance; series resistance with fixed head; parallel resistance with fixed head, and with fixed heads; two pipelines in series, with a side outlet; and series-parallel resistance with different fixed heads. It also tells how to specify the required head for a given flow. Pump and resistance curves In order to analyze pump circuits, we need equations describing pump head vs. capacity and pipe-circuit re- sistance vs, flo ‘The relationship between head and capacity for a cen- twifugal pump may be expressed as a quadratic equatio Haat ie w where 11 is head (fi) and Q is volumetric capacity or flow (gpm). ‘Thus, the three constants a, 6 and ¢ completely specify @ pump curve. A pump maker may supply the constants, or they can be extracted by analyzing the pump curve For example: A centrifugal pump is rated at 500-ft head for 50-gpm capacity. The pump curve shows that head at 0 gpm is 550 ft, and head at 37.5 gpm is also 550 ft. Substituting 550 fe and 0 gpm in Eq, 1, we find that a 60 ft. Substituting a and the other two points into Eq, 1, and solving the two equations simultaneously, we find Originally published August 22, 1983. Mahesh Talwar, The Ralph M. Parsons Co. that b = 3.03 and c = —0.0806, Thus, the head-vs.-capac- ity equation for this pump is: H = 550 + 3.03Q ~ 0,0806(" @ Pipeline resistance is the head that the pump must overcome. When flow is turbulent, the frictional resist- ance (Ry, fi) may be expressed a Ry = 0.031 1/LQa @) where f is the Darcy friction factor, L is the equiva length of pipe (fi), and d is the pipe diameter (in,). Thus, for a constant diameter and length, frictional resistance may be expressed as: By= he (a) 1¢ value of k can be determined empirically by measur- ing pressure drop (head loss) at some turbulent flow Q and dividing by Q®. Since pipe may vary in diameter, and there may be branches, it is usually necessary to add several such fric- tional resistances. The total resistance to flow (R,) includes the fixed head—ie, static head plus any in- crease in pressure, Suction lines are typically sized for 1 ft or less frictional loss, but this is not part of R,. Rather than develop more equations, let us now look at the simplest type of pump circuit and analyze it. For this, and for each of the other circuits, we will show how. to estimate the actual performance of a pump in the cir= cuit, and offer an example. We will also show how to. specify the pump needed to develop a given flow. Case 1: Series resistance Fig. | shows a simple circuit made up of two pipes connected in series to a single pump. ‘The head-vs.- capacity (H-Q) curve is characteristic of the pump. The resistance curves labeled Ry and Ry are for the two pipe sections; their sum is the total-resistance curve R,. ‘These curves assume no fixed head. That is, they assume that: ‘Terminal pressure + terminal static pressure = Origin pressure + origin static pressure Point P is the operating point for this pump in this84 CENTRIFUGAL PUMPS Negligible resistance A circuit, and H, and Q, are the associated head and flow, How can we find this mathematically? For two pipes in series, the head at the operating point, is the sum of the resistances, and the flow is the same in both pipes. These equations describe the operating point H,=Ry+ Re ©) Q=Q=QW (6) The resistances are frictional, so we can rewrite Eq. 5 as: Hy = (hy + hae Substituting Eq. 1 for H,, and solving for Q,: at 1Q, + QE = (hy + Qe (8) 2 Fe = ie he) uy ® Once Q, is known, H, can be calculated via Eq. 1, and thus the operating point is determined. For example: Suppose that the pump’s H-Q equation is known, and the constants are as follows: a = 104 ft; b 0.08 fugpm; ¢ = —0.005 fu{gpm?. Suppose further thatthe resistance constants for the two pipes in series are: hy = 0.015 fUgpm?; ky = 0.02 fugpm?. What is the pump's operating point? From Eq. 9, Q, = 50 gpm. From Eq. 1, H, = 87.5 ft Case 2: Parallel resistances Fig. 2 shows one pump feeding two parallel lines, and the corresponding pump and resistance curves. Again, ‘we assume that there is no fixed head. = one 2H i ' : i = | = i 3 | | i | o a, o a, a tow ncaa) Flow or capacity (2) (Case 1: Series resistance Fig.1 Case 2: Parallel resistance Fig. 2 ‘The héad here is the same in each line, and the total flow is the sum of the flows in the two lines. These equa- tions describe the operating point: Hyp=Ry= Re 0) Q=Q+ Qe an ‘The resistance of each line is: H,= Ry = Qh Hy = Ro = hy (12) From this we can show that: H, = (UVR, + UV) 7? (13) Setting this equal to Eq. 1, and solving for Qr, we obtain: g- 8 Vb? = date = (WV, + VVIa) *) 2e— (Vi + Vy?) Once Q, is known, H, can be calcutated via Eq. 1, and thus the pump’s operating point is determined. Then Qy and Qy can be calculated from Eq, 12. For example: Suppose that the pump equation and (4) the pipe resistance are the same as in Case 1. For two pipes in parallel, what is the pump’s operating point? From Eq. 14, Q, = 101.5 gpm. From Eq, 1, H, = 444 ft. From Eq. 12, Q) = Vii; = 54:4 gpm. Likewise, Q = 47.1 gpm. Case 3: Series resistance fixed head Fig. 3 shows one pump feeding a series of two lines, as, in Case 1. But here there is a fixed head, or static head, defined as: H, = Terminal pressure + terminal static pressure — origin pressure ~ origin static pressureANALYZING CENTRIFUGAL-PUMP CIRCUITS 85 Negligible Fy fy ‘ . ] Fy ~ 7 a g a 2 Pun i Pop 5 cee 8 fe | 8 g ! a $n, 1 3 7% ag 1 = 8 fort Bh = i E Ss toy { fe ao i £ | pu oa 02,0, a Flow or capacity (0) Flow or capacity (Q) Case 3: Series resistance with fixed head Fig. 3 For this arrangement, these equations describe the oper- ating point H,= + Ry + Ry (15) Q=Q=B (16) Substituting Ry + Ry as derived in Case 1 into Eq, 15: Hy =H, + (hy + kv an Setting this equal to Eq. 1, and solving for Q,, we obtain: b= VF 4a Hye— hh —&) 2- 2 — hy = ha) Once Q is known, H, can be calculated via Eq. 1, and thus the pump’s operating point is determined. For example: Suppose that the pump equation and the pipe resistance are the same as in Case 1. For (wo pipes in series, and a fixed head of 20 ft, what is the pump’s operating point? From Eq. 18, Q = 44.8 gpm. From Eq. 1, H, = 9044 Note that the fixed head does not offset the pump's H-Q curve in Fig. 8 Case 4: Parallel resistance with fixed head Fig. 4 shows the arrangement for this case: two pipes in parallel, and a fixed head defined as in C For this arrangement, the operating point is described by: H,=H,+ Ry =H, + Ry (19) Q= A+ Q (20) Following the saine route as in Case 2, we can show: 121+ (Vin + VES) (18) Case 4: Parallel resistance with fixed head Fig. 4 Setting this equal to Eq, 1, and solving for Q,, we obtain a= a bs VE = da = Me — WV, + UVB) fe - (Vy + VI) Once Q, is known, H, can be cal thus the pump’s operating point and Q, can be calculated as in Case 2. For example: Suppose that the pump equation and the pipe resistance are the same as in Case 1. For two pipes in parallel, and a fixed head of 20 ft, what is the pump’s operating point? 5h From Eq. 22, = 90.8 gpm. From Eq, 1, H, = Then Qy = VH-Hyky = 48.7 gpm, and Q, = 42.1 gpm, Case 5: Parallel, with different fixed heads Fig. 5 shows the arrangement for this case: two pipes in parallel, wit fixed heads #1, in the first pipe and Hy this arrangement, these equations dle- scribe the operating point: (22) Hy = Hy + Ry = Ha + Ry 23) Q=AtQ (2a) Asin Case 2, we can now substitute AQ? for R in Eq. H,~ Hy Ry = kQt Hy ~ Ha = Ry = hi 26) Solving for Q, and Qu: Q = WH, Hah en Qe = V(H, ~ Have (28)86 CENTRIFUGAL PUMPS, Negligible «|S one Head (H) or resistance (f) Head (M1) or resistance (R) ‘Adding these up, and substituting for H, from Eq. 1, we obtain: error solution is needed to get Q,. Once Q, is known, H, can be calculated via Eq. 1, and thus the pump’s operat- ing point is determined. Then Q) and Qy can be calcu- lated from Eq, 27-28 For example: Suppose that the pump equation and the pipe resistance are the same as in Case 1. For two pipes in parallel, with a fixed head of 20 ftin the first and 40 fin the second, what is the pump’s operating point? From Eq. 28, by trial and error, Q, = 85 gpin. From Eq. 1, H, = 61.1 ft. From Eq. 27-28, Q, = 52.3 gpm and Qe = 32.7 gpm. Case 6: Series resistance, with a side outlet Fig. 6 shows the arrangement for this case: two pipes in series, with an outlet between them. The flow through the outlet (Q,) is known; there is no fixed head. For this arrangement, these equations describe the operating point H,=Ry+ Re (30) Q=Q +2 1) Following the same route as in Case 1, we can show: H,= hh + hQ - Q) (32) Flow or capacity (Q) Case 6: Seri resistance, with a side outlet. Fig. 6 Setting this equal to Eq. 1 and solving for Q,, we obtain the following: (2ksQe +b) 2(e~ hy he) VE ii: ia Ne~ hy — ky) 33) (= hy — hy Once Q, is known, 11, can be calculated via Eq, 1, and thus the pump’s operating point is determined. For example: Suppose that the pump equation ane the pipe resistance are the same as in Case 1. For two arallel, and a side-outet flow of 25 gpm, what is the pump's operating point? 60.7 gpm. Thus Qy = 60.7 gpm and gpm. From Eq, 1, H, = 80.7 ft s and parallel resistance Fig. 7 shows the arrangement for this complicated pipe circuit: one pump feeding a single line that splits into two. The fixed head is assumed to be different (Ho and H,) for cach of the two discharge lines, For this arrangement, these equations describe the operating point H,= Hat Ri + Re=Hat Ri +Ry (34) Q=Q= At Qs (35) As in Case 5, we can now substitute AQ? for R in Eq. 34 anil get head in terms of flow: H, ~ Hyg = Ry + Ry = hy? + bo H, ~ Ha = Ry + Ry = hi + kG 36) (37)ANALYZING CENTRIFUGAL-PUMP CIRCUITS. 87 Flow of capacity (2) and parallel resistance Fig.7 Solving for Qe and Qs Qe = VT, Ha hi (38) Qs = Vl, Hs Oy (39) Adding these together, and substituting Eq, 1 for #, g-\o , oS WG = He, yt# + (c= k)Q hs This cannot be solved algebraically. Thus, a error solution is needed to get Q,. Once Q, is known, H, canbe calculated via Eq, 1,and thus the pump’s operat- ing point is determined. Then Qe and Q; can be calcu- hated from Eq. 38-39. For example: Suppose that the pump equation is the same as in Case 1, and the resistance constants are: ky = 0.008; ky = 0.015; ky = 0.02. For the series-parallel ar- rangement in Fig. 7, with a fixed head of 20 ft in the second line and 40 ft in the third, what is the pump's operating point? From Eq, 40, by trial and error, Q, From Eq. 1, H, gpm and Qs Specifying a pump’s rated head Now that we have seen what a given pump will deliver ina given circuit, et us look at how to specify the pump required to deliver a given flow. The procedure is straightforward: Find the total re- sistance (R,) or head (H,) asa function of Q,, then plug in Q = 62.8 gpm. 79.3 ft. From Eq. 38-39, Q = 43.0 19.7 gpm. the desired Q, to get the head. Three examples serve to illustrate this. Case | example: For the system shown land described in Case 1, what rated head is needed to deliver 50 gpm? From Eq Hy = (hy + byQe = (0.015 + 0.020)(50)° = 875 ‘Thus the pump needed is one rated 87.5 fi at 50 gpm, Case 2 example: For the system shown in Fig. 2 and described in Case 2, what rated head is needed to deliver 100 gpm? From Eq, 13: H, = (WVky + UVR) 2Q? VV0.015 + 11V0.020)-2(100)? = 43.1 ‘Thus the pump needed is one rated 43.1 ft at 100 gpm, Jase 3 example: For the system shown in Fig. 3 and described in Case 3, what rated head is needed to deliver 45 gpm? From Eq. 17: A, = H, + (hy + by 20 + (0.015 + 0.02)(45)* = 90.9 ‘Thus the pump needed is one rated 90.9 ft at 45 gpm. Analytical vs. graphical Now that we have seen the analytical approach to esti- mating flow or head for seven different pump-and-pipe ircuits, what about the graphical approach? As Figs. 15 indicate, the total-resistance curve is not difficult to put together: For series resistances, and fixed head, the }Aotal-resistance curve is the sum of the resistances at any given flow. For parallel resistances, the total-resistance curve is the sum of the flows at any given head, Once the total-resistance curve is drawn, the operating point is where this curve intersects the pump curve. However, the systems in Fig. 6~7 are not so simple. And for any case a graphical solution requires plotting of several curves, so that any errors in the curves can add up. In contrast, the analytical formulas can give decimal- point accuracies, quickly. The limits on this analytical approach are that the pump curve must be reduced to a quadratic equation, and that flow must be turbulent, The author Mahesh Talwar an engine i the wena pct of The ah Parsons oy Ee Annex GF 218160 Wot Walna St, Pasadena, CA 9113, ere he sce i desig al plans Pg des ‘impute prams dase arene Me Talwar ha BS degree um the Benaes Hina University tote of Teg, and-an MS. degre fom Cabra Ste Pager Unter, bah in cherie cogiecing He wegen afr and amenber of AICHE andthe Sic af Petroleum Engineers ofthe Asian Tat ‘of Mining, Metallic sd Perle Engincers