Pump and System Interaction

Conflict Resolution:
Pump & System Interaction
April 13, 2017

Agenda
 What is a system curve and  Complex curves

what is it good for? – Multiple branch points
 Friction vs. static head – Different liquid level elevations
dominated systems – System curves that change
 Effects of manual vs. control over time
valves – Effect of control features
 Affinity laws – Multiple system curves for a
single system
 Parallel composite curves
 Problems creating system
– When will parallel pumps
give more flow vs. when curves
they won’t - and why  API 610 and ANSI/HI 9.6.3-
– Effects of dissimilar pumps 2017 best practices
 Series composite curves
April 13, 2017 Pump & System Interaction 2
Pumps and Systems
 A pump must overcome two fundamental system-related

aspects
– Friction
– Static
• Liquid elevation differences between supply and discharge
• Pressure differences between supply and discharge*
» E.g., when tanks are pressurized
Elevation Changes, Same Pressure in Tanks Elevation Same, Different Pressure in Tanks
P1 P2
Supply Discharge Supply Discharge
* Since the effects of supply and discharge pressure differences are the same as liquid elevation
differences, we will simplify things and only discuss elevation differences in this course, with the
understanding that pressure differences can cause the same effects

What Is a System Curve?
 A system curve represents the head required to move fluid

through a system at various flowrates
 In the absence of control features, the system will operate
where the pump and system intersect

What Is a System Curve? (2)
Pump Curve
Friction Hf Total Dynamic

Head
System Curve
Head (TDH)
Static Hs
Flowrate
Operating
Flowrate

What Are System Curves Good For?
 System curves help demonstrate pumping system behavior in

a graphical manner
 If a system curve can be determined, it can help identify the
effects of pump and/or system modifications
 As systems get more complex, system curves lose usefulness
and in fact it is not possible in some cases to determine a
unique system curve

Friction in Pump Systems
 Friction occurs in pump systems due to irrecoverable

hydraulic losses in:
– Piping
– Valving
– Fittings (e.g., elbows, tees)
– Equipment (e.g., heat exchangers)
 Friction is also used to control flow or pressure
– Automated flow and pressure control valves
– Orifices
– Manual throttling valves

Friction Characteristics
 It is often convenient to think of pump systems in terms of

head rather than pressure
 Head loss and pressure loss are related
∆P = ρg∆H
 Frictional head loss typically depends on the square of
velocity and flow rate
2
 fL  V
∆H =  
 D  2g
2
 fL  Q
∆H =  
 D  2gA 2
∆H = RQ 2
Pure Friction System Curve
 For systems with pure friction Pump Curve

the system curve head goes to
zero at zero flow
 Closed systems are always
Head
purely frictional
 Any pump can produce flow System Curve Hf
(no elevation to overcome)
Flowrate
Example: No Elevation Changes
Supply Discharge

Effect of Elevation Differences
 When the supply or discharge Pump Curve System Curve
liquid elevation is changed, the

system curve shifts up and
down
Head
 When there is a liquid
elevation increase, no flow can
occur unless the pump
generates at least enough
Flowrate
head to over come the Elevation Changes
elevation increase Example:
Supply Discharge

Effects of Elevation Differences (2)
New System Curve
(With Increased Static Head)
Pump Curve Old System Curve
New TDH
Old TDH
Hf*
Hf
Head
Increased
Static Head
Hs
Hs
Flowrate Old New

Old Flow
New Flow
* In this case, friction head Hf decreases because the flow rate is reduced
Static Head Dominated Systems
 A system that is static head dominated is one where the

primary effect of the pump is to overcome static head (i.e.,
gravity, or liquid elevation)
Large Elevation Change
Pump Curve
System Curve
Hf
Head
Hs
Supply Discharge
Flowrate

Effect of Control Valves
 Control valves (CV) are a form of frictional head loss

Pump Curve System Curve
Head Loss Hcv

Across CV
Hf Hf
Head
Hs Hs
Flowrate w/o CV with CV

Flow Flow
with CV w/o CV
Effect of Manual Throttling Valves
 Manual valve throttling increases the friction head loss

System Curve Valve Throttled
Pump Curve System Curve Valve Open
Hf
Hf
Head
Hs Hs
Flow Valve Valve Valve Throttled

Flowrate Flow Valve
Open Open
Throttled

Pump Affinity Laws
 The pump affinity laws (also known as homologous pump

laws) are based on dimensional analysis and allow prediction
of pump performance for other impeller sizes and speeds
Q1  D1   N1 
=   =   Where:
Q2  D2   N2 
2 2 Q = Flowrate
∆H1  D1   N1 
=   =   D = (Impeller) Diameter
∆H 2  D2   N2  N = Speed
H = Head
3 3
P1 D  N  P = Power
=  1  =  1 
P2  D2   N2 

Impeller Size Changes
 Using the affinity laws the pump head curve can be adjusted
for a different diameter impeller
Pump Curve 100%

Impeller Diameter
Head
System Curve
Pump Curve 90%
Impeller Diameter
Flowrate
Pump Speed Changes
 Similar to impeller diameter, using the affinity laws the pump

head curve can be adjusted for a different speed
Pump Curve 100% Speed

Head
System Curve
Pump Curve 90% Speed
Flowrate
Pump Efficiency Effects
Pump Head Curve
Pump Efficiency Curve
Efficiency
Head
System Curve
Flowrate
Operating Flowrate
Best Efficiency Point

Pump Efficiency Effects (2)
 The efficiency of a pump does not change significantly with

speed
2 −3
η1  Q1  ∆H1  P2   N1  N1   N2 
=     =      =1
η2  Q2  ∆H2  P1   N2  N2   N1 
 Similarly, but to a lesser degree, the same is true for impeller

changes

Pump Efficiency Effects (3)
 Iso-efficiency lines on a head/flow diagram follow the behavior

of head (quadratic) and flow (linear)
40% Efficiency
60%
50%
70%
80%
82%
80%
100% Speed
Pump Head Curves

90% Speed
Head
80% Speed
70% Speed
60% Speed
Flowrate

Variable Speed Pumping Efficiency
 Friction dominated system curve parallels iso-efficiency lines

System Curve (Friction Dominated)
Efficiency
40%
60%
50%
70%
80%
82%
80%
100% Speed
Pump Head Curves

90% Speed
Head
80% Speed
70% Speed
60% Speed
Flowrate

Variable Speed Pumping Efficiency (2)
 Static head dominated system curve doesn’t parallel iso-

efficiency lines
Efficiency System Curve
40%
60%
50%
(Static Head Dominated)
70%
80%
82%
80%
100% Speed
Pump Head Curves

90% Speed
Head
80% Speed
70% Speed
60% Speed
Flowrate

Parallel Composite Pump Curves
 All parallel pumps are the same size

Head
One Two Three

Pump Pumps Pumps
Flowrate

Steep System Curve With Parallel Pumps
Flow increase very small with additional pumps (in this case)
System Curve
Head
One Two Three

Pump Pumps Pumps
Flowrate

Flat System Curve With Parallel Pumps
Flow increase much larger with additional pumps (in this case)
System Curve
Head
One Two Three

Pump Pumps Pumps
Flowrate

Dissimilar Parallel Pumps
Head
Pump 1+2
Pump 1 Pump 2
Flowrate

Series Composite Pump Curves
 All series pumps are the same size
Three
Pumps
Two
Pumps
Head
One
Pump
Flowrate

Complex System Curves
Head
Supply Discharge
Flowrate
* From the “Pump Handbook”, Karassik et al.

Complex System Curves (2)
 The flow rate for a system curve is typically referenced to a

pump
 System curves can be generated with reference to other
locations in the system
 Some systems (especially those with multiple pumps) may not
have a unique system curve
– In such cases, the concept of a system curve breaks down, and
system curves have no real value

Elevation Changes
Example:
System Curves Over
Time: Tank Filling Supply Discharge
New System Curve

(With Increased Static Head)
Pump Curve Old System Curve
New TDH
Old TDH
Hf*
Hf
Head
Increased
Static Head
Hs
Hs
Flowrate Old New

Old Flow
New Flow
System Curves Over Long Time Periods
System and Pump Degradation New System Curve
(With Increased Friction)
Original Pump Curve Original System Curve
New TDH
Original TDH
New Pump Curve
(Degraded Head)
Hf Hf*
Head
Hs Hs
Original New
Flowrate Original Flow
New Flow

System Curves Over Long Time Periods:
System Degradation with Control Valves
New System Curve
(With Increased Friction)
Pump Curve Original System Curve
Head Loss Head Loss Hcv

Across CV Across CV Hcv
Originally New
Hf Hf
Head
Hs Hs
Flowrate with CV with CV

Flow Flow Original New
with CV w/o CV

Tank B
Multiple System Curves
Different System Operations * Tank A
Tank C
Supply Discharge
* From
* From the “Pump
the “Pump Handbook”,
Handbook”, Karassik
Karassik et al.et al.

AFT Fathom Detailed Data on Pump vs.
System Curves *
* From the “Pump Handbook”, Karassik et al.

* New feature in release 2017.03.31
Problems Creating System Curves and
Composite Pump Curves
 Heat transfer occurs or anything that changes density
– System curves are based on head and the concept of head
breaks down when the density changes
 Multiple pumps in parallel when the pump piping is not
symmetrical
– If the flows through the pumps are not equal then:
• a unique system curve cannot be created
• the heads through the pumps are usually different and it is not
possible to say what the composite “head” actually is
– Often the composite system curve and composite pump curve do
not cross at the operating point
• The operating point itself is not well defined

Composite Pump Curves (2)
Total = 2540 Avg = 56.5

Composite Pump Curves (3)
Total Flow = 2540 gpm

Avg Head = 56.5 ft
?
Pump Efficiency Effects
Pump Head Curve
Pump Efficiency Curve
Efficiency
Head
System Curve
Flowrate
Operating Flowrate
Best Efficiency Point

API 610 and BEP
 5.1.14 Pumps shall have

a preferred operating
region of 70% to 120%
of best efficiency
flowrate of the pump as
furnished. Rated flow
shall be within the
region of 80% to 110%
of best efficiency
flowrate of the pump as
furnished.

ANSI/HI 9.6.3-2017

Reliability vs. Distance from BEP
Source: Barringer, H.P., 1997 “Reliability Engineering Principles” training course,

slide 45, Barringer & Assoc. Humble, TX
Vibration vs. Distance from BEP
Thrust Bearing / Horizontal
Overall Vibration Vs. Flow
Fixed Speed w/ Control Valve vs Variable Speed
0.9 Model 3175

0.8 4X6-18
0.7
0.6
Vibration (IPS)
Test 11 Variable
Speed Test 17.5" Dia
0.5 Test 1 1785 Rpm
17.5" Dia
0.4
0.3 Magenta – Fixed Speed

Blue – Variable Speed
0.2
0.1
BEP
0
0 500 1000 1500 2000 2500
Flow (GPM)
Source: ITT IBG Goulds Pumps

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Conflict Resolution:

Pump & System Interaction

April 13, 2017

 What is a system curve and  Complex curves

 A pump must overcome two fundamental system-related

Supply Discharge Supply Discharge

April 13, 2017 Pump & System Interaction 3

 A system curve represents the head required to move fluid

April 13, 2017 Pump & System Interaction 4

Friction Hf Total Dynamic

April 13, 2017 Pump & System Interaction 5

 System curves help demonstrate pumping system behavior in

April 13, 2017 Pump & System Interaction 6

 Friction occurs in pump systems due to irrecoverable

April 13, 2017 Pump & System Interaction 7

 It is often convenient to think of pump systems in terms of

 For systems with pure friction Pump Curve

Example: No Elevation Changes

April 13, 2017 Pump & System Interaction 9

 When the supply or discharge Pump Curve System Curve

liquid elevation is changed, the

April 13, 2017 Pump & System Interaction 10

Pump Curve Old System Curve

Flowrate Old New

 A system that is static head dominated is one where the

April 13, 2017 Pump & System Interaction 12

 Control valves (CV) are a form of frictional head loss

Head Loss Hcv

Flowrate w/o CV with CV

 Manual valve throttling increases the friction head loss

Flow Valve Valve Valve Throttled

April 13, 2017 Pump & System Interaction 14

 The pump affinity laws (also known as homologous pump

April 13, 2017 Pump & System Interaction 15

Pump Curve 100%

 Similar to impeller diameter, using the affinity laws the pump

Pump Curve 100% Speed

Pump Head Curve

Pump Efficiency Curve

April 13, 2017 Pump & System Interaction 18

 The efficiency of a pump does not change significantly with

 Similarly, but to a lesser degree, the same is true for impeller

April 13, 2017 Pump & System Interaction 19

 Iso-efficiency lines on a head/flow diagram follow the behavior

Pump Head Curves

April 13, 2017 Pump & System Interaction 20

 Friction dominated system curve parallels iso-efficiency lines

Pump Head Curves

April 13, 2017 Pump & System Interaction 21

 Static head dominated system curve doesn’t parallel iso-

Pump Head Curves

April 13, 2017 Pump & System Interaction 22

 All parallel pumps are the same size

One Two Three

April 13, 2017 Pump & System Interaction 23

One Two Three

April 13, 2017 Pump & System Interaction 24

One Two Three

April 13, 2017 Pump & System Interaction 25

April 13, 2017 Pump & System Interaction 26

 All series pumps are the same size

April 13, 2017 Pump & System Interaction 27

* From the “Pump Handbook”, Karassik et al.

April 13, 2017 Pump & System Interaction 28