Anal yang 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. ‘Mahesh Tabwar, The Ralph M. Parsons Co. O 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-rs-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-flow 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- Wieldy when the circuit is complicated by branches, drawoffs, and differing elevations. The other approach also gets complicated, but less so, and a mathematical so- lution can be programmed. ‘This article offers a mathematical approach to estimat- ing flow and head fora 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 different fixed heads; co cs 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. flow. “The relationship between head and capacity for a cen- trifugal pump may be expressed as a quadratic equation: 7 H=atiQrg ® where H is head (fi) and Qis volumetric capacity or flow (gpm), Thus, the three constants a, b and'c completely specify a 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 hhead at 0 gpm is 550 ft, and head at 37.5 gpm is also 550 fi. Substituting 550 ft and O gpm in Eq. 1, we find that a = 550 ft Subwtituting a and the other (wo points into Eq. 1 and solving the Wo equations simultaneously, we find that 6 = 8.08 and ¢ = ~0.0806. Thus, the head-vs-capac- ity equation for this pump is: -H = 530 + 3.03 - 0.08069" ® Pipeline resistance is the head that the pump must overcome. When flow is turbulent, the frictional resist- ance (Ry, ft) may be expressed as: Ry= O01 YLQE 8) where f is the Darcy friction factor, L is the equivalent length of pipe (f), and dis the pipe diameter (in). Thus, for a constant diameter and length, frictional resistance may be expressed as: R= “ “The value of kcan be determined empirically by measur- ing pressure drop (head loss) at some turbulent flow Q and dividing by @*. Since pipe may vary in diameter, and there may be branches, iis usually necessary to add several such fiie- tiomal resistances. The total resistance to flow (R,) also includes the fixed head—ic, static head plus any in- ‘reasein pressure. Suction lines are typically sized for I ft (oF 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. 1 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 Re are for the two pipe sections; their sum isthe 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 NTR ET 698 resistance Fig. 1 oH ie 8 g 5 nme 3 oH he, coe t o 7 3 En & 3 U 1 = i 3 i ° @, Flow or caacty (0) Cate 1: Se Fig.2 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+Ry ® 2=A=& © ‘The resistances are frictional, so we can rewrite Eq. 5 as: H,= (hy + bX ® Substiuting Eq, 1 for H,, and solving for Q: 2+ 1, + oF = hy + Ie ® _ cb Vitale hy = By) 2 (=I, =) ® 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; 6 = 0.08 fgpm; c= =0.005 f'gpm?. Suppose further that the resistance constants for the two pipes in series are: ky = 0.015 fUgpm*; ky = pump’ operating point? From Eq. Eq. 1H, = 875 ft Case 2: Parallel resistances “ee Fig, 2 shows one pump feeding two parallel lines, and the corresponding pump and resistance curves. Again, wwe assume that there is no fixed head. Q, = 50 gpm. From. .02 fugpm?. What is the , ‘The head 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: H,=Ry=Re (10) — Q=Ate an ‘The resistance of each line is Hy= Ry =h@is Hp=Rr=h@ (12) From this we can show that: 5 A, = (Vig + WV) (1s) Setting this equal to Eq. 1, and solving for Qr, we obtain: = abe VER tte Vi 3 IVS, Qe = (Vy + VV a) *) Once Q, is known, H, can be calculated via Eq. 1, and thus the pump’s operating point is determined. Then Q, and Qz can be calculated from Eq, 12. For example: Suppose that the pump equation and the pipe resistance are the same as in Case 1. For two pipes in parallel, what is the pymp’s operating point? From Eq, 14, Q, = 101.5 gpm. From Eq. 1, Hy = 444 ft. From Eq. 12, Q) = Vidhy = 54.4 gpm. Likewise, Q= 47.1 gpm. : «aay - Case 3: Series resistance with fixed head Fig. 3 shows one pump feeding a series of two lines, as, in Case 1. But here there isa fixed head, or static head, defined as: ‘H, = Terminal pressure + terminal static pressure ~ origin pressure ~ origin static pressure 70 NR RGR I ° Rg € O22 URE F. aeHead (#1) or resistance (R) mos z Head (1 or resistance (A) Flow or capacity (@} Case 3: Series resistance with fixed head ig. 3 Flow or cazacity (0) Case 4: Parallel resistance with fixed head For this arrangement, these equations describe the oper- ating point: H,=H,+R\+ Re as) Q=Q=e (16) Substituting Ry + Re as derived in Case 1 into Eq. 15: H, = H, + (ha + by? an Setting this equal to Eq, 1, and solving for Q,, we obtain: @ Be hy h) cy) Once Q, is known, H, can be calculated via Eq, 1, and thus the pumps operating point is determined. For example: Suppose that the pump equation and the pipe reqwaance ae the same az in Case I. For two Pree in acres anda fixed fad of 20 ft, what i the Pumps operating point? Fonte 18, 0, © 448 gpm. From Eq, 1, #1, = 90.4 f [Note that de fixed ead does nat offset the pump's H-Q curve in Fig 3. Parallel resistance with fixed head s the arrangement for this case: two pipes d asin Case 3. For this H, = H+ R= H+ Re ag) Q=Ate (20) Following the same route as in Case 2, we car’ show: H, =U, + (UV i + UVR PE ly Setting this equal to Eq, 1, and solving for Q,, we obtain: e- ab VP ae HEWN INE) 9) Be - (Vk, + UV?) Once Q,is known, H, canbe calculate via Eq, and thas the pumps operating points determined. Then Qy and Qy can be clelated 38 in Case 2 Yor example: Suppose that the pump equation and the pipe resotance are the sane tin Case 1. For wo Pie parallels and a fied head of 20 f, what isthe Pe We 33 0.00.8 gpm, From Eq, 1, H, = 55.58 om Ey 22,0. 90,8 gpm. From Fq, 1, H, = 35.58. ‘Then Qi = VHi-Fiyh, = 48.7 gpm, and Q. = 42.1 gpm. Case 5: Parallel, with different fixed heads Fig. 8 shows the arrangement for tis case: two pipes parallel, with fixed heads #1, in the first pipe and Ha in the second. For this arrangement, these equations de- scribe the operating point: H,= Ha +Ry= Hat Ra es) Q=Atee 4 ‘Asin Case 2, wecan now substitute kQ* for R in Eq. 23: Hy ~ Hy = R= iQ (25) Ha = Ry = Qe 26) Solving for Qr and Qo: Qi = VET Hak en = VE Have 8) AEROS AT n sentonovtanecaL recur cnetiy Negigibe resistance ‘ fy Head (H) or resistance (F } = = Head (H) or resistance (7) = Flow or eapacity (0) Case 5: Parallel resistance with different fixed heads Fig. 5 T l a Flow or capacity (O) (Case 6: Series resistance, with aside outlet Fig. 6 Adding these up, and substituting for H, from Eq, 1, we obtain: += Hy hy * TET (FREE This cannot be solved algebraically. Thus, a trialand- 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 Qs 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 fein the firstand 40 fc in the second, what isthe pump's operating point? From Eq, 28, by trial and error, Q, = 85 gpm. From Eq, 1, H, = 61.1 ft. From Eq, 27-28, Q, = 52.3 gpm and Q ='327 gpm. gs 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: i Hy= Ry +Re 60) QHW-Vr+®] en Following the same route as in Case 1, we can show: iG + belQ, ~ QY* @2 Setting this equal to Eq, 1 and solving for Q, we obiain the following: Q = Oke to Be = hy = ha) (ROEDER te = Ba = ha) Once Q, is known, #, 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 two pipes in parallel, and a side-outlet flow of 25 gpm, what is the pump’s operating point? From Eq. 33.Q, = 60.7 gpm. Thus Q, = 60.7 gpm and Q. = 35.7 gpm. From Eq. 1, H, = 80.7 ft Case 7: Series and parallel resistance Fig. 7 shows the arrangement for this complicated pipe circuit: one pump feeding a single line that splits into (wo. The fixed head is assumed to be different (fa and 3) for each of the wo discharge lines. For this arrangement, these equations describe the operating TREY (as) * Hes Hat Rit+Re=Hat y+ Ry (34) D=U= VAD 35) As in Case 5, we can now substitute AQ? for R in Eq. 34 and get head in terms of flow: H,-Ha=Ri+Re=hG+h@G 06) H,-Hy=Ri+R=hE+hG 82)ain 38) and ind wo tis tits ng Flow or capacity (0) Case 7: Series and parallel resistance Solving for Qo and Qs: = VE, Ha~ hh (38) Qs= Vi, Ha = h@ yh 69) ‘Adding these together, and substituting Eq. 1 for Hy: a0 © WE= A, nS a + att e~ WE Hs z 40) “This cannot be solved algebraically. Thus, a triahand error solution is needed to get Q- Once Q, is known, H,can be calculated via Eq, 1,and thusthe pump's operat ing point is determined. Then Qz and Qs can be caleu- lated from Eq. 38-39. For example: Suppose that the pump equation is the same asin Case I, aid 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 pumps operating point? ‘From Eq, 40, by tial and error, Q, = Q, = 62.8 gpm. From Eq. 1, H, = 79.3 ft. From Eq, 38-39, Qe = 43.0 gpm and Q; ='19.7 gpm. Specifying a pump’s rated head ‘Now that we have seen what a given pump will deliver i reuit, let us look at how to specify the pump or a given Hove © iy stvaightforward: Find the total re- sistance (ft) oF head (74) a8 a function of @,, then plugin the desired Q, to get the head. Three examples serve to illustrate this. Case | example: For the system shown in Fig. 1 and described in Case 1, what rated head is needed to deliver 50 gpm? From Eq. 7: af H,= (hy + hg? = (0.015 + 0.020)50)* =875 ‘Thus the pump needed is one rated 87.5 ft 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, = (UVR + UV 70E = (WVO.015 + 17V0.020)-*(100)* = 43.1 “Thus the pump needed is one rated 43.1 fc at 100 zpm. ‘Case 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: H, = Hy + hy +h = 20 + (0.015 + 0.02)(45)" = 90.9 ‘Thus the pump needed is one rated 90.9 fe 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 CGreuits, what about the graphical approach? As Figs. 1-3 indicate, the totabresistance curve is not difficult to put together: For series resistances, and fixed head. ‘the total-resistance curve is the sum of the resistances at any given flow. For parallel resistances, the tota-resistance Eurveis 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 plorang of several curves, so that any errors in the curves ean add up. ‘In contrast, the analytical formulas can give decimal- point accuracies, quickly. The limits on this analstcal Epproach are that the puimp curve must be reduced to a Quadratic equation, and that flow must be turbulent. Mark Lipowt=.Eior ‘The author Mabe Taw i an ener in “Tet wine eu mel oon wtp ec Sattar ich aad ee 's eum nr ie er f Bae Nese