Understanding NPSH
When Pumping
Settling Slurry
Aleks Roudnev, Weir Slurry™ North America
Beware!
Cavitation on slurry starts at higher
suction pressure than on water.
H
ardly any publication
related to NPSH goes
without references to
“most misunderstood, misused,
or creating most confusion.” This
applies at least twofold to cases
when a centrifugal pump handles
slurry. Before digging into this
issue, though it makes sense to
refresh the basic terms related to
pump suction conditions.
The total suction head (hs) is
defined in the Hydraulic Insti-
tute Centrifugal Pump Tests
Standard [1] as the algebraic sum
of the suction gauge head (hgs)
plus the velocity head (hvs =
v12/2g) at point of gauge attach-
ment plus the elevation head (Zs)
from the suction gauge centerline
to the pump datum. On slurry
pump installations gauges at suc-
tion are seldom used. The suc-
tion gauge reading corrected to
pump centerline datum equals
the suction head minus velocity
head. With this in mind, hs is the
static head on the pump suction
above the pump centerline
minus all friction head losses (hf)
for the flow rate being considered
(including entrance and fitting
losses in the suction piping) plus
any “blanket” pressure existing in
the suction supply. For a typical
24 SEPTEMBER 2004
slurry pump installation, as
shown in Figure 1, with suction
supply under atmospheric pres-
sure only (no blanket pressure in
tank):
hs = Z0 - hf
In absolute terms the total
suction head, or energy present
at the impeller inlet, is expressed
in units of length, or, more accu-
rately, of liquid column height,
as follows:
hsa = pa/γ + Z0 - hf
where pa is an atmospheric pres-
sure in barometric or gauge units,
and γ is a specific weight of
pumped liquid. Reference specific
weight of water at 20° C equals γ =
ρg = 998.2*9.81 = 9.79x103 N/m3.
Atmospheric pressure expressed in
terms of water column height
equals 10.34 m (34 ft).
To avoid cavitation in the
pumping of liquids, the pressure
at any point in the suction line
must never be reduced to the sat-
urated vapor pressure (pv) of the
liquid. Although slurry pumps
due to their rugged design are
less susceptible to cavitation
damage, it is an undesirable
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condition that may cause the
reduction in pump head and effi-
ciency, excessive wear to pump
components, and bearing failure.
Pressure drops occur due to
losses in piping and local flow
acceleration at the impeller inlet.
The available energy that can be
utilized to get the liquid through
the suction piping and suction
waterway of the pump into the
impeller is thus the total suction
head less the vapor pressure of
the liquid at the pumping tem-
perature. The resulting available
head—measured at the suction
opening of the pump—repre-
sents “net positive suction head
available,” commonly indicated
by its initials, NPSHA:
NPSHA = (pa - pv)/γ
+ Z0 - hf
Equation 1
NPSHA is a characteristic of
a system, and represents the dif-
ference between the existing
absolute suction head and vapor
pressure at the given tempera-
ture. A different characteristic,
NPSHR, stands for “net positive
suction head required” by the
pump and depends on pump
design. It is obtained by the cen-
trifugal pump test on water and
represents the minimum margin
between the suction head and
vapor pressure required for
proper pump operation. In
accordance with current practice,
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Figure 1. Total suction head and NPSHA for typical slurry pump installation.
the NPSHR data on pump per-
formance curves represent values
at which the total head of a sin-
gle stage pump will be reduced
by 3% of its full published value.
Both NPSHA and NPSHR
values change with variation in
the pump flow rate at a given
speed, as illustrated in Figure 2.
The available NPSH is reduced
with increase in flow rate by the
friction loss in the pipe. The
required NPSH, being the func-
tion of velocities at the impeller
inlet and pump suction passages,
increases at a rate close to square
of the flow rate. An appropriate
NPSH margin should be provid-
ed by the system above the pub-
lished NPSHR to ensure a reli-
able pump operation.
Looking at the equations
and graphs in Figures 1 and 2, it
becomes apparent that the total
suction head and NPSHA at a
given operating temperature
depend on the following factors:
a) installation conditions, such
as presence of “blanket”
pressure, and location, such
as elevation above sea level,
affecting atmospheric pres-
sure pa;
PUMPS & SYSTEMS
b) system design, such as suc-
tion pipeline layout, affect-
ing hydraulic friction losses
hf;
c) pump operating point on
the performance curve, relat-
ed to velocity head
hvs=v12/2g;
d) specific gravity of the
pumped liquid, which
affects the value of pa/γ
Test Work to Date
Slurries in mineral process-
ing are typically water based, of
settling type, and at ambient or
slightly higher temperatures.
Much of the test work has
addressed slurry pump suction
performance on such settling
slurries.
Mashin [2] conducted labo-
ratory experiments on a 5” end
suction slurry pump with 330
mm impeller, handling sand slur-
ry of 1.15 specific gravity and
mean particle diameter of 1 mm.
He concluded that the NPSH
required by centrifugal pump on
this type of slurries was the same
value as on water, with no addi-
tional correction required for
solids. It means that cavitation in
the pump when handling slurry
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starts at higher suction pressure
than on water.
NPSHRm = NPSHRW
Equation 2
Herbich and Cooper [3]
came to the same conclusion
testing dredge pumps on settling
slurries, as did Kirillov and
Smoilovskaya [4] based on series
of tests with slurries containing
solid particles of different sizes at
various concentrations.
Strictly speaking, Equation
(2) is only true if slurry at the
impeller inlet behaves as a homo-
geneous liquid, i.e. velocities of
water and solid particles are
equal. Settling slurries with small
to medium size solids usually fall
into this category.
It is necessary to point out
that some of the studies in deter-
mining the critical NPSHR
focused on the point of substan-
tial (well beyond 3%) head drop
[2, 4], also called NPSHfull cavitation.
This has allowed for better corre-
lation of results with the physics
of the cavitation process because
it corresponds to the existence of
well-developed vapor cavern, or
bubble, attached to the vane
leading edge and extended
towards the impeller outlet. It
makes it difficult, however, to
relate the test results to accepted
industrial practice of 3% head
drop criterion.
A good example is suction
performance of a 5” end suction
slurry pump tested in laboratory
conditions while handling sand
and gravel slurries with various
sizes of solids [4]. Pump operat-
ing points during tests varied
between 80%, 100% and 120%
of the BEP flow rate. Slurry den-
sity changed between 1025 and
1280 kg/m3. The test rig had a
closed loop configuration with a
capability of pressure change by
evacuating air from the system.
SEPTEMBER 2004 25

Figure 2. Available and required NPSH change with flow rate at given speed.
Partial NPSH curves, pre-
sented in Figure 3a and 3b, were
analyzed using a 3% head drop
criteria currently accepted as the
industry practice. Points corre-
sponding to NPSHR at 3% head
drop are marked on the descend-
ing portion of each curve as
NPSH 3%. Only fragments of
full test curves at BEP flow rate
are shown here. More detailed
description of the results can be
found in [5].
NPSH tests on slurry are dif-
ficult to conduct, especially at
higher concentrations and larger
size solids, so, a certain scatter of
points can be expected. It
appears, however, that there is a
trend toward some increase in
NPSH 3% value on slurry as
compared to that on water. It
happens mainly because the
shape of the curve bend seems to
Figures 3a and 3b. Partial NPSH curves for a 5” end suction slurry pump for water, sand d50=0.2 mm(a) and gravel (b)
mixtures of different densities and solid sizes, with marked 3% head drop points.
26 SEPTEMBER 2004
become more gradual with
increased solids size and slurry
density.
Straight vertical dashed lines
correspond to constant NPSH
equal to NPSH 3% on water.
Solid curved lines represent an
attempt to accommodate a possi-
ble variation of NPSHR for dif-
ferent slurries using a head de-
rating factor Hr=Hm/Hw
obtained from comparison of sta-
ble (“cavitation-free”) portions of
the analyzed curves. For tested
mixtures the Hr ranged between
1.00 and 0.85. It should be
noted that there is no sound sci-
ence behind this attempt, which
should be treated purely as a
numerical exercise.
The Solids Effect
One possible way to address
the solids effect on NPSH, when
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pumping settling slurries, is to
say that prediction of NPSHRm
being completely equal to
NPSHRW at 3% head drop looks
too optimistic. At the same time,
assuming that NPSHRm does
change following (numerically)
the head reduction due to solids
is more conservative.
To avoid cavitation damage,
NPSH available on site must
always be higher than the NPSH
required by the pump. NPSHA
must be calculated taking into
account the density of slurry and
other site data. Substituting
water-solid mixture with an
equivalent homogenous liquid:
NPSHA =
(pa/γ1 - pv/γ1) + Z0 - hf
Equation 3
where γ1 =
specific weight of slurry
Suction line total friction
losses on slurry may also be dif-
ferent from water values, but, in
case of a short suction line, the
difference is negligible.
The usual assumption in
slurry pumping practice is that
there should not be a problem
with cavitation as long as flooded
suction condition is present. In
most cases, this is true. However,
in the case of low slurry level
PUMPS & SYSTEMS
SEPT04PUMPS&SYSp18-28 8/19/04 1:23 PM
above suction centerline, espe-
cially with suction lift, available
NPSH needs to be calculated to
ensure that proper NPSH mar-
gin is present [6]. According to
the HI Standard for NPSH
Margin [7], which is currently
under revision, slurry pumps
should operate with NPSHA of
at least 10%, or 0.6 m (2 ft),
whichever is greater, above pub-
lished NPSHR.
Consider a slurry pump with
a 650-mm inlet size, installed on
cyclone feed duty, at a mine site
located at an elevation of 4,500
meters above sea level. Slurry
flow rate is 6000 m3/h, specific
gravity of slurry relative to water
1.65, and temperature 18°C.
The published curve indicates
NPSHR at the pump operating
point of 6.5 m absolute. Cal-
culated head de-rating factor Hr
equals 0.92. Suction line com-
bined friction head loss is 0.5 m
(assume no change from slurry to
water). We want to know what
minimum sump level should be
maintained for proper pump
operation.
To answer this question,
Equation 3 should be solved for
minimum Z0 based on minimum
NPSHA of 6.5/0.92x1.1=7.77 m,
according to [7]. Exercising a
conservative approach, the pub-
lished pump NPSHR value of
6.5 m is divided by the head de-
rating factor of 0.92.
Z0min = NPSHAmin -
(pa/γ1 - pv/γ1) + hf
Equation 4
Atmospheric pressure at the
4500 m elevation is 57.58 kPa,
saturated vapor pressure corre-
sponding to 18° C equals to 2.01
kPa.
PUMPS & SYSTEMS
Page 27
Z0min = 7.77 – (57.58 –
2.01)*1000/(9.79*1000
*1.65) +0.5 = 4.83m
Note that, if the pump were
pumping clear water, minimum
sump level could be much lower:
Z0min = 7.15 – (57.58 –
2.01)*1000/(9.79*1000)
+0.5 = 1.97m
Here we take the NPSHR at
its published value of 6.5 m abso-
lute, and the resulting minimum
NPSHA for a proper margin
becomes lower as well. And, if
the pump is installed at the sea
level with atmospheric pressure
of 101.325 kPa, it could run
with suction lift:
Z0min = 7.15 – (101.33 –
2.01)*1000/(9.79*1000)
+0.5 = -2.49m
The pump will operate satis-
factorily in the described slurry
circuit only if the slurry level in
sump is kept at or above calculat-
ed minimum of 4.83 m, al-
though the “flooded suction”
condition is satisfied with lower
sump level. While the net posi-
tive suction head required by the
pump does not change much,
the available NPSH of a system
becomes quite different in com-
parison to pumping water at sea
level. Two factors contribute to
the available NPSH adjustment.
First, atmospheric pressure is
reduced due to high altitude and
is now equal to 57.58/9.79 =
5.88 meters of water column.
Second, the specific gravity of
slurry further reduces the atmo-
spheric pressure to 5.88/1.65 =
3.56 meters of liquid column.
We can also determine what
the suction gauge reading would
be (if a suction gauge were
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installed) for the first two cases.
Based on the total suction head
definition:
hgs = hs – v12/2g
or, in pressure units:
hgs = (Z0 – hf – v12/2g)*γ
Velocity in 650 mm suction pipe
line: v1 = 5.02 m/s.
Suction gauge reading on slurry
at minimum sump level:
hgs=(4.83-0.5 -
5.022/(2*9.81))
*(9.79*1000*1.65)/1000
= 41.12 kPa
Suction gauge reading on water
at minimum sump level:
hgs=(1.97-0.5-5.022/
(2*9.81))
*(9.79*1000)/1000
= 23.75 kPa
This exercise confirms that
cavitation on slurry will start at
higher suction pressure than on
water.
Conclusions
In summary, for water-based
slurries of settling type, most of
the test work published to date
supports the equivalent liquid
approach, which allows us to
consider NPSH required for slur-
ry to be equal to that on water. A
detailed comparison of NPSH
curves at a 3% head drop level
showed some trend towards
increases in NPSHR following
the increase in head de-rating
coefficient Hr due to solids.
Various industrial slurry
handling applications include
pumping viscous and non-
Newtonian slurries, such as
SEPTEMBER 2004 27
SEPT04PUMPS&SYSp18-28 8/19/04 1:23 PM
pastes or suspensions, and frothy
mixtures containing solids along
with dissolved or entrained air or
gas. In situations like these, the
net positive suction head
required by the pump cannot be
assumed the same as that on
water. Thus, different correction
methods need to be employed.
References
1. ANSI/HI 1.6-2000, Ameri-
can National Standard for
Centrifugal Pump Tests, Hy-
draulic Institute, Parsippany,
NJ, USA www.pumps.org
2. Mashin, A. N., Cavitation
Performance of Dredge Pumps
on Water and Slurry,
Technical Information Bul-
letin No 5, VIGM, Moscow,
1954 (in Russian)
3. Herbich, J.B., and Cooper,
R.L., II, “The Effect of
Solid-water Mixtures on
Cavitation Characteristics of
Circle 111 on Reader Service Card
28 SEPTEMBER 2004
Page 28
Dredge Pumps,” Proc.
Fourth World Dredging
Conference, New Orleans,
LA, 1971
4. Kirillov, V.V., and Smoil-
ovskaya, L.A, “Cavitation
Performance of Slurry
Pumps Handling Mixtures
with Various Size of Solids,”
Advancing Technology of
Minerals Excavation and
Processing, MoscowVNIIP-
Istromsirjo, 1984, pp. 141-
144 (in Russian)
5. Roudnev, A.S. “Slurry Pump
Suction Performance Consi-
derations,” Proc. 16th Intl.
Conference on Hydrotrans-
port, BHR Group, Santiago,
Chile, 2004, pp. 137-150
6. Roudnev, A.S., “Under-
standing NPSH When
Pumping Slurry, Part 1,”
Weir Slurry Pipeline,
Volume 2, pp. 5-7, Weir
Slurry North America, 2003
www.pump-zone.com
7. ANSI/HI 9.6.1-1998, Amer -
ican National Standard for
Centrifugal and Vertical
Pumps for NPSH Margin,
Hydraulic Institute, Parsip-
pany, NJ (www.pumps.org).
Aleksander S. (Aleks) Roudnev is
Manager of Research and Develop-
ment at Weir Slurry Group North
America (WSNA) in Madison, WI,
where he is primarily responsible for
design and development of heavy-duty
centrifugal slurry pumps. A 35-year
veteran of the pump industry, prior to
joining USNA, he was a Director of
R&D at Envirotech Pumpsystems in
Salt Lake City, UT, and also had held
various positions in engineering and
management at NPO VNIIGidro-
mash in Moscow. Roudnev holds an
M.S. degree in Mechanical Engineer-
ing from Bauman Moscow State
Technical University and a Ph.D. in
Mechanical Engineering from All-
Union Research Institute of Hydraulic
Machines in Moscow. E-mail him
directly at aleks.roudnev@weirslur-
ry.com
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PUMPS & SYSTEMS