2015

General Lecture

Cavitation & NPSH

By Dr. Ali Hammoud

Professor in Fluid mechanics
& Hydraulics machines

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 Cavitation can be termed as
“the heart attack of the pump”.
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EDU-2012 3
Cavitation Damage

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Evidence of Cavitation

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EDU-2012 6
EDU-2012 7
 Cavitation
The formation and collapse
of vapor bubbles in a
liquid.

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 General notes
• Pumps can pump only liquids ,
not vapors.
• Rise in Temperature and fall in
Pressure induces vaporization.

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 Mechanism of
Cavitation
• The phenomenon of cavitation is
summarized as follows:
• 1- Formation of bubbles inside the liquid
being pumped.
• 2-Growth of bubbles
• 3- Collapse of bubbles

Cavitation
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 Cavitation
The formation of bubble occurs at
point where the pressure is less than
the vapor pressure, and bubble
collapse occurs at a point where the
pressure is increased to the vapor
pressure.

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 General information
•The job of a centrifugal pump is to generate
enough pressure to overcome system hydraulic
resistance & elevation difference .

•But if the suction pressure is too low, the

hydraulic losses can “eat away” enough pressure
so that it could drop below the liquid vapor
pressure.

•If there is a lot of bubbles in the impeller

inlet, the impeller may become “vapor locked,”
and the pump will stop delivering flow.
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 Boiling

Boiling without heat

Boil a liquid with heat

If you keep the temperature

constant and lower the pressure
the liquid will also boil.

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Vapor –Liquid curve

Liquid

Adding
Heat

Vapor

BAU -tripoli /Dr.Hammoud 14

 Boiling

14.7 psi

212 F

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 Boiling

Adding
Heat

14.7 psi

212 F

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 Boiling

Adding
Heat
Combination
Lowering
Lowering Pressure &
Pressure Addition of
Heat

14.7 psi

212 F

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 Temp C V.pressue Density
KN/m2 Kg/m3

liquid phase 15 1.71 999

20 2.36 998
25 3.16 997
30 4.21 996
35 5.61 994
40 7.36 992
45 9.55 990
50 12.31 988
60 19.9 984
70 23.15 978
80 47.77 972
90 70.11 965
100 101.3 958
The pressure at which the liquid vaporizes is known as the
vapor pressure and it is specified for a given temperature. 18
 Cavitation & NPSH

If the water pressure is low enough to reach water

vapor ,vacuum is achieved and water will boil at room
temperature EDU-2012 19
Cavitation begins ,
when the pressure in the suction side of the pump
near to the “Eye “of the pump drops below
atmospheric pressure, it may approach the vapor
pressure of the liquid. If this occurs, liquid boils up
quickly. The bubbles form at the position of lowest
pressure at the pump inlet, which is just where the
fluid being acted upon ( D) by the impeller vanes,
they are ,then rapidly compressed. The compression
of the vapor bubbles produces a small shock wave
that effects the impeller surface and pits away at
the metal creating large eroded areas and subsequent
pump failure.

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Pressure profile inside the pump
Pressure
Pressure increase due to impeller
“Discharge” Pd
E- “Eye”

D
Point of lowest Pressure D

Flow
S E D Discharge
S “Suction”
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 Close View of Cavitation
Pressure @ T= 20 C Water evaporate
@ Pv=2.36
“Discharge” KN/m2
Pd
E- “Eye”

D Water vapor Pressure

Pv=2.36

Flow
S E D Discharge
S “Suction” BAU -tripoli /Dr.Hammoud
22
Close View of Cavitation

Impeller

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Close View of Cavitation
Impeller cavitation region

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Close View of Cavitation
Point of lowest Pressure
Pressure

D “Discharge” D
E- “Eye” formation

Cavitation
S Liquid
Vapor
E
Collapse
Boiling

Flow
S E D
S “Suction”
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 Close View of Cavitation
• Collapse of vapor bubble suddenly change its
phase from vapor to liquid at very high velocity
which impact shock wave on the surface of the
impeller which can reach a value around 12000
Psi .This pressure capable to deform the metal of
the pump creating pitting. It is important to
remember that , this process IS NOT ONE TIME
EVENT ,it will be repeated 2400 time each
minutes this may lead to erode the metal and
damage the pump.

BAU -tripoli /Dr.Hammoud 26

 The pitting effect is illustrated schematically As
follows:
Vapor
Pressure

After the bubble collapses, a shock wave emanates outward from the point of collapse. This27
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shock wave is what we actually hear and what we call sound of "cavitation"
Cavitation damage

Implosion of bubbles
 Energy Release
• Energy released by bubble collapse is intense,
but on a microscopic scale .
Some references [3]& [4] claimed that, during
cavitation
• Pressure – more than 12000 Psi ( 816 bar)
• Velocity – more than 300 ft/sec ( 90 m/s)
• Time – less than 2 microseconds
• Repeatability – 200-300 times per second
29
 Symptoms of Cavitation
Cavitation in pumps can often be detected by a
characteristic generated sound. It sounds like gravel
in a concrete mixer.
Cavitation lead to excessive vibration, fatigue and
greatly increased wear of pump parts such as bearing
failures , sealing leakage , Metal gets corroded seen
as small pitting's.
Cavitation Loss in pump performance reduces the flow
rate , head & efficiency of the pump & life time.
“Water has a Milky shape”
“Material
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failure” 30
Cavitation Affects on Pump Performance
1. Reduction in capacity of the pump:
The formation of bubbles causes a volume increase , and decreasing the
space available for the liquid and thus diminish pumping capacity.
2. Decrease in the head developed: reduces the head of the pump life

Pump Performance
Curves at various
suction lift with
Cavitation

H
As a general rule, centrifugal
pumps located less than 4-5
metres above the water level
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should not experience 31
Q cavitation
 The NPSH Required
varies with speed and
capacity within any
particular pump. Pump
manufacturer's curves
normally provide this
information.

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Again !
As bubbles flow from low pressure to
higher, they implode against metal
surfaces. These micro-hammer-like
impacts erode the material, creating
cavities – thus “cavitation”

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 General energy equation between 1 & 2
s

P1 V12 Ps V22
  Z 1  hL    Z2
1  2.g  2.g

Ps P1 V22
  ( Z1  Z 2 )   hL V1 0
  2.g [

PS
hms Manometric suction head .
 The minimum suction pressure at
the inlet of the pump is:
P1
 hatm Atmospheric pressure
 V 22
 (Z1  Z 2 )  hss
hms  hat m  hss   hL
Static suction head
2.g
hss < 0 (That means the pump has to overcome the elevation
difference, the head loss in the
34 suction pipe and the
change in kinetic energy).
 In terms of head, the minimum suction
pressure at the inlet of the pump is:

V s2
hms  hatm  hss   hL
2.g
S

This is the minimum suction pressure head

at the inlet of the pump.

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In terms of head, the minimum suction pressure at the inlet of the pump is:

2
Vs
hms  hatm  hss  hL 
2.g
This is the minimum suction pressure head at the inlet of the pump. (That
means the pump has to overcome the elevation difference, the head loss in the
suction pipe and the change in kinetic energy).

In reality, the minimum pressure does not exactly occur at the

inlet of the pump, but there is an additional pressure drop
inside the pump due to the change in flow direction from axial
to radial at very high rotational speed of the impeller ( Forced
vortex) . This action leads to an increase in eddy losses and
sudden increase in flow velocity followed by reduction in
pressure at the vane of the impeller as shown in figure below
2/18/2015 NDU
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/ ASME 36 36
 Point “D”
Minimum
pressure

2/18/2015 NDU
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/ ASME 37 37
2/18/2015 NDU
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/ ASME 38 38
 hmin  hms  X hms hmd

X= Dynamic head
depression or deficiency
due to impeller rotation (
forced vortex)

X   hmd

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 X  function of hmd (if hmd then X )
X   hmd
  Cavitation Factor Function of specific speed Ns
Then the minimum pressure becomes

hmin  hms  X hms hmd

2
Vs
hmin  hms   hmd  hatm  hss  hls    hmd
2g
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 To prevent cavitation hmin must greater then
vapor pressure hvapor.

Pmin  Pvap

hmin  hvap
Pv
In term of head Where  hvap


hms   hm  hvap

2
Vs
hms   hm  hatm  hss  hls    hm  hvap
2g
41
 2
Vs
hatm  hss  hls    hm  hvap
2g
2
V
hatm  hvap  hss  hls  hm  s

2.g
hatm  hvap  hss  hL s  NPSHA [User]
2
V
 hm   NPSHR
s
[manufacturer]
2.g

NPSHA > NPSHR 42

 The NPSH Required
varies with speed and
capacity within any
particular pump. Pump
manufacturer's curves
normally provide this
information.

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NPSH available  hatm  hvap  hss  hL hss  0
P1 Pv
NPSH available   ( Z1  Z 2 )  hL
 
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Net Positive Suction Head Available (N.P.S.H.A.)
The Net-Positive Suction Head Available (N.P.S.H.A.)
is the total energy per unit weight, or head, at the
suction flange of the pump minus the vapor pressure
head of the fluid. This is the accepted definition that
is published by the Hydraulic institute’s Standards
books
The term "Net" refers to the actual head at the
pump suction flange which should be “Positive” , since
some energy is lost in friction prior to the suction.
NPSHavailable  Psuction - Psaturation  0
P1 EDU-2012
Pv
45

{  (Z1  Z2 )  hL }  0
 Net positive suction head required

Net positive suction head required for the

pump is the absolute pressure head in
meters that the pump can overcome the
pressure drop through the pump and
maintain the majority of the liquid
above the vapor pressure.
NPSHA is NOT simply the level of liquid in the suction tank…

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In order to avoid cavitation and guarantee proper operation of the
pump, it is desirable to have more NPSH available than it is required
since this allows more flexibility in operation and adds insurance
towards satisfactory performance.

P1 Pv
NPSH available   ( Z1  Z 2 )  hL  NPSH Required
 
Or NPSH available  hatm  hvap  hss  hL

NPSH available  NPSH Required  Safety margin

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 Related to pump
NPSHR manufacturer

NPSH Available Related to pump

User

It is a function of the system in which the pump operates.

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 How many times NPSH-A can be higher
than NPSH-R?

As a guideline, the NPSH-Available should exceed

the NPSH-Required by a minimum of 5 feet (1.5 m), or be
equal to 1.2-2.5 times the NPSH-Required, Suggested by
(Hydraulic Institute Standard (ANSI/HI 9.6.1)

NPSH available  NPSH Required  1.5m

2/18/2015 NDU / ASME 50

 To prevent Cavitation possible solutions are

1- Correct selection & installation of pump

2- Case of circulated pump the decrease the fluid temperature if
possible or (locate the circulated pump in the return pipe).
3-Increase the pressure at the pump inlet (Locate the reservoir at
higher level or pressurize the tank if possible )
4- Select a pump with lower rotational speed if possible .
5- Minimize the head loss due to pipe friction and fittings if possible.
6-Reduce the NPSHR by using an inducer impeller .The inducer can
cut net positive suction head required (NPSHR) by almost 50%
7-Be sure the tank vent is open & not obstructed

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CAPACITY CHANGE EFFECT ON NPSH R
Critical range
NPSHA

Recommended
operating range

Non-recommended
NPSHR Limiting flow operating range
Increased flow
Designed flow

Flow (m3/Hr) Q1 Q2 Q3
EFFECT OF PUMP TEMPERATURE ON NPSH
Pump temperature was designed for 160OC. At 180OC, NPSHA was
inadequate and cavitation will occur.

NPSHA
160OC

170OC

180OC

NPSHR

Flow (m3/Hr) QD
EFFECT OF PUMP LOCATION ON NPSH
As the location of the pump has been changed from the original
position, NPSH has decreased.

NPSHA (old location)

NPSHA (New location)

NPSHR

Flow (m3/Hr) QD
EFFECT OF SPEED CHANGE ON NPSH
With speed increase, NPSH R also goes up and will reduce the margin
available in NPSH A.

NPSHA

NPSHR-high speed

NPSHR-low speed

Flow (m3/Hr) Q-low Q-high

• To reduce the NPSHreq:
• pump with less circular velocity.
• more pumps or using a double-suction eyed pump
• specially designed suction-eye propeller (only specific volumetric flow
rates).

• Ways to increase NPSHA:

• putting suction source or total system under pressure to increase
pump suction pressure
• if fluid temp. is high, feed source should be on a higher position than
pump and under pressure
• low fluid velocity
• reducing the losses in suction pipe
 INDUCER

Low NPSH applications

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 INDUCER
HOW does it work?

pressure drops below vapor

pressure pressure
 Evaporation & Steam
bubbles
 implodes at area of
higher pressure =
CAVITATION

Suction
pressure
Mini
Vapor pressure pressure
Safety margin
At higher Temperature
absolute
pressure 0
stream line

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 INDUCER
HOW does it work?

pressure

H impeller
H total
Suction NPSH
pressure inducer H indcer

Vapor pressure

absolute
pressure 0
stream line

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The Universal Inducer enables a safe
and reliable operation with low NPSH
values, the handling of liquids close to the
boiling point and the handling of fluids
containing entrained gas. The wide operating
range allows operation at small capacities
without inadmissible recirculation and
vibrations, and therefore improves the safety
in operation of the pump in process
applications. These characteristics have a
positive effect for the durability of bearing
and shaft seal, which leads to a decrease of
the life cycle costs (LCC).

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A pump is pumping water from a closed tank as shown in the
accompanied figure . The water temperature is 60C and the gage
pressure in the closed tank is 20 kPa. The atmospheric pressure is taken
as 100kPa. The water level in the closed tank is 2 m above the pump
inlet. The total head loss in the suction pipe is 1.5 m. Find the available
NPSH for the present system. (Assuming the value of (NPSH)minimum
is 3 m).

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Suppose a pump is located, at sea level and is pumping water from a tank as shown
below. The pump centerline is 3.5 m above the surface of the water in the reservoir,
which is open to the atmosphere. The head loss in the suction line is 1.5 m. If the
vapor pressure of the water is 2,36 KN /m2 :
1- Is the pump safe from cavitation effects? (Assuming the value of (NPSH)minimum
is 3 m).

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How do the pump manufacturers measure N.P.S.H.
required? The pump manufacturers measure the
N.P.S.H. required in a test rig similar to
that shown in the corresponding Figure.
The system is run in a closed loop where
flow, total head and power consumed
are measured. In order to provide a low
N.P.S.H., a vacuum pump is used to
lower the pressure in the suction tank
that will provide a low head at the
pump suction. The pressure in the
suction tank is lowered until a drop of
3% (see next figure ) of the total head is
measured. When that occurs the
N.P.S.H. is calculated and recorded as
the N.P.S.H. required for that operating
point. The experiment is repeated for
many operating points. Heating coils are
also used to increase the water
temperature thereby increasing the
vapor pressure and further lowering the
N.P.S.H. as needed.
2/18/2015 NDU / ASME 63
EDU-2012 63
Hydraulic Institute define the NPSHrequired as such value
of NPSHR when a pump losses 3% of its developed head.
They call this NPSHR3%

For simplicity, they just write it as

NPSHR, implying 3% 64
In other words “The NPSH-Required is defined as the
NPSH applied to the pump at a given flow rate which causes
sufficient cavitation to reduce the Total Dynamic Head
(TDH) by 3%.”

NPSH3%

2/18/2015 NDU / ASME 65

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Increasing the system pressure at the suction branch, to prevent cavitation problems ,

insoluble
is often

problem and considerable costly.

 Conclusion

Cavitation and NPSH seem to be some of the

least understood topics associated with pump
applications. To some engineers, these topics
appear mysterious or, at best, are only partially
understood.

67
FEND
68
Recirculation: at low flow and high flow compared to EDU-2012
the flow at the B.E.P. the
fluid will start to recirculate or move in a reverse direction at the suction and at
the discharge.

It is well established that

cavitation type of damage
seen on the inlet vanes
and not associated with
inadequate NPSH can be
directly linked to the
pump operating in the
suction recirculation
zone. Similar damage seen
on the discharge vane tips
can also be associated
with pump operation in
the discharge
recirculation zone.

69
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The suction and discharge recirculation may occur at different points as
shown on the characteristic curve below.

70
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71
 full boiling
growth
A lot of bubbles…
More bubbles…

Incipient

Head, ft
NPSHRR
3%

NPSHR3%
NPSHA, ft

Concept of incipient cavitation, bubble formation and growth, to full boiling.

EDU-2012 72
 BEP
Eff

NPSHA
NPSHR

Trouble!
Flow

Velocities are higher at higher flow – this lowers static pressure, requiring
more pressure to counteract that As a result, NPSHR rises at higher flow..

EDU-2012 73
Actually, at low flow bad things begin to happen…

Suction Recirculation starts here…

NPSHR

Flow

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 IMPELELLER EYE SIZE EFFECT
NPSHR

recirculation

no recirculation
14 ft

10 ft

Flow
Smaller eye helps suppress suction recirculation, although with some sacrifice of NPSHR
at BEP

EDU-2012 75
 References
• 2. “Understanding Pump Cavitation”, Chemical Processing, Feb 1997, W.E. Nelson
• 3. “Centrifugal pumps operation at off-design conditions”, Chemical Processing April, May,
• June 1987, Igor J. Karassik
• 4. “Understanding NPSH for Pumps”, Technical Publishing Co. 1975, Travis F. Glover
• 5. “Centrifugal Pumps for General Refinery Services”, Refining Department, API Standard
• 610, 6th Edition, January 1981
• 6. “Controlling Centrifugal Pumps”, Hydrocarbon Processing, July 1995, Walter Driedger
• 7. “Don’t Run Centrifugal Pumps Off The Right Side of the Curve”, Mike Sondalini
• 8. “Pump Handbook”, Third Edition, Igor j. Karassik, Joseph P.Messina, Paul cooper
• Charles C.Heald
• 9. "Centrifugal Pumps and System Hydraulics", Chemical Engineering, October 4, 1982,
• pp. 84-106. , Karassik, I.J.,
• 10. Unit Operations of Chemical Engineering (5th Edition), McGraw-Hill, 1993, pp. 188-
• 204. , McCabe, W.L., J.C. Smith, and P. Harriott,
• 11. “CAVISMONITOR: Cavitation Monitoring In Hydraulic Machines With Aid Of A
• Computer Aided Visualization Method”, Bernd Bachert, Henrik Lohrberg, Bernd Stoffel
• Laboratory for Turbomachinery and Fluid Power Darmstadt University of Technology
• Magdalenenstrasse 4, 64289 Darmstadt, Germany
• 12. “The Hydraulic Pump Inlet Condition: Impact on Hydraulic Pump Cavitation Potential”,
• G.E. Totten and R.J. Bishop, Jr.Union Carbide Corporation Tarrytown, NY
• 13. "Study of Cavitation Collapse Pressure and Erosion, Part I: A Method for Measurement
• of Collapse Pressure", Wear, 1989, Vol. 133, p.219-232, T. Okada, Y. Iwai and K.
• Awazu,
• 14. “Key Centrifugal Pump Parameters and How They Impact Your Applications” Part 1
• Pumps and Systems: They Go Together, Doug Kriebel, PE, Kriebel Engineered
• Equipment
• 15. “How to compute Net Positive Suction Head for centrifugal pumps”. J. J. Paugh,
• P.E.Vice President, Engineering, Warren Pumps Inc.
• 16. “New Monitoring System Warns of Cavitation and Low-Flow Instabilities”, APRIL 1996
• PUMPS AND SYSTEMS MAGAZINE, Robert A. Atkins, Chung E. lee and Henry F.
• Taylor
• 17. “Detecting Cavitation in Centrifugal Pumps”, Experimental Results of the Pump
• Laboratory, Jeremy Jensen Project Engineer, Bentley Rotor Dynamics Research
• Corporation
EDU-2012 76