Efficiency and Input Power of the Pump

The work performed by the pump is equal to the weight of liquid

pumped in Unit time multiplied by total Head in meters. However the
pump capacity in M 3 /hr and liquid specific gravity are used rather than
weight of liquid pumped for work done by the pump.
The input power “P” of a pump is the mechanical power
in kW or Watt taken by the shaft or coupling. So the input power of the
pump also called Break Horse Power (BHP).
Pump input BHP is the power delivered to the pump shaft and is
designated as brake horsepower. so pump input power also called
as pump shaft power.
Pump output power is called as Water Horse Power (WHP )
or Hydraulic power and it is useful work delivered by the pump. and is
usually expressed by the formula
Hydraulic power Ph = Flow rate X Total developed head X Density
X Gravitational constant
Pump Efficiency is the ratio of pump input and output power.
i.e Efficiency of the pump is the ratio water horse power to break horse
power.

Pump input power calculation formula or pump shaft power

calculation formula
Pump Input Power = P
Formula – 1

P in Watt =
Here
Q = Flow rate in m 3 /sec
H = Total developed head in meters
= Density in kg/m 3
g = Gravitational constant = 9.81 m/sec 2
η = Efficiency of the pump ( between 0% to 100%)
Formula – 2

P in kW =
Here
Q = Flow rate in m 3 /hr
H = Total developed head in meters
= Density in kg/dm 3 (1 kg/m 3 = 0.001 kg/dm 3 )
η = Efficiency between 0 and <1 (not in %)

Formula – 3

P in kW =
Here
Q = Flow rate in Lt./sec ( 1 m 3 /sec = 3.6 x Lt./sec)
H = Total developed head in meters
= Density in kg/dm 3 (1 kg/m 3 = 0.001 kg/dm 3 )
η = Efficiency of the pump ( between 0% to 100%)
Formula – 4

P in Hp =
Here
Q = Flow rate in Lt./sec
H = Total developed head in meters
= Density in kg/dm 3
η = Efficiency of the pump ( between 0% to 100%)
Formula – 5 ( USCS units )

P in Hp =
Here
Q = Flow rate in gpm
H = Total developed head in feet
= Density in lb/ft 3
η = Efficiency of the pump ( between 0% to 100%)
For an electric-motor-driven pumping unit, the overall efficiency is
Overall efficiency = pump efficiency x motor efficiency
The overall efficiency then becomes what is commonly called “wire-to-
water” efficiency, which is expressed by the formula

Overall Efficiency =

Specific Speed of Pump

The specific speed “Nq” is a parameter derived from a dimensional
analysis which allows a comparison of impellers of various pump sizes
even when their operating similar Q -H range. The specific speed can
be used to classify the optimum impeller design.
Specific Speed of pump (Nq) is defined as the speed in RPM at which
a geometrically similar impeller would run if it were reduced
proportionately in size so as to delivered 75 kg of water per second to
the height of 1 m.
Nq is also defined as the theoretical rotational speed at which a
geometrically similar impeller would run if it were of such a size as to
produce 1 m of head at a flow rate of 1 m 3 /sec at the best efficiency
point.
The specific speed can be made a truly dimensionless characteristic
parameter while retaining the same numerical value by using following
equation.
Metric System

Nq = =
Where Nq = Dimensionless parameter
N = RPM of pump
n = Rev/sec of Pump
Q = Flow rate in m 3 /sec
H = Head in meters
g = Gravitational constant ( 9.81 m/sec 2 )
British Units

Nq =
Where N = RPM of pump
Q = Flow rate in Gallons per minute (GPM)
H = Head in feet
Note:
1. For multistage pumps the developed head (H) at best efficiency
2. Consider half total discharge in case of double suction impeller.
Approximate reference values for specific speed of centrifugal
pump (Nq):
Radial high head impeller – up to approx. 25
Radial medium head impeller – up to approx. 40
Radial low head impeller – up to approx. 70
Mixed flow impeller – up to approx. 160
Axial flow impeller (propeller) – approx. from 140 to 400
Affinity laws for pumps – Please go through the below link
Affinity laws for centrifugal pumps | Positive displacement pump affinity
laws | Pump affinity laws with example

Why to select pump with better efficiency

Pump Efficiency is the most important factor while calculating power
consumption. So while selection of the higher rating of pump always
choose best efficiency pump set.
The following formula to help which type of efficiency rating pump is
best
N
N = Number units power saving per year in KWH

= Higher and lower overall efficiency of two pump sets.

P = Power input in kW to motor (related to low efficiency pump)
T = Running hours per year

Pump efficiency calculation example

= 75% and 65% respectively
P = Power input = 40 kW
T = 3000 hours per year
N = 18461 Units (KWH)
So for same rating pump efficiency will increase by 10% then power
saving will be 18461 KWH per year.

Centrifugal pump power calculation online

Note : 1000 kg/m 3 = 1 kg/dm 3
How to read a pump Curve
Pumps are often considered as a machine which will provide a required flow and pressure,
however in reality the performance of a pump is dictated by a performance curve detailing how
the pump will provide a range of flows at differing pressures.

Pumps provide a differential pressure and flow according to their installation. As there are 3
main families of pumps being Centrifugal, Rotary Positive Displacement and Reciprocating
Positive Displacement which have different characteristics dependent on the circumstances they
face.

What is a pump performance curve?

Pumps are a simple machine which provide a performance based on the system it works in, as
most pumps do not have a control interface unless fitted with a pressure transducer and variable
frequency drive (VFD) and must be manually commissioned onsite.

A pumps performance will be inline with the pressure losses in the system, with pumps
producing a differential flow and pressure based on the conditions at the inlet. A pump curve is a
graphical representation of what flows and differential pressures can be produced by a pump.

As 90% of problems with pumps are caused by the system they are installed in, it is important to
note that pump selection is just part of the process of selecting a pump which is right for the
process.

In order for a pump to be selected for your process it is important that the following are known:
1. Fluid being pumped
2. Application
3. Flow Required
4. Pressure required
5. Viscosity of fluid & Specific Gravity
6. Temperature
7. Power available / Power medium being used to drive pump.
There are two types of pump curves dependent on the pump selected, which are Centrifugal
Pumps and Positive displacement Pump Curves.

Centrifugal Pump Curve

Centrifugal pumps account for 70% o

f pumping applications, and

their curves are generally shaped with a half moon shape with the highest point on the left
showing highest pressure but lowest flow, and the far right end of curve showing highest flow
but lowest amount of pressure. The duty point is is marked typically with the efficiency indicated
in percent.

The numbers at the end of the curve is the impeller diameter, which is trimmed to acheive the
required flow and pressure. The more an impeller is trimmed the higher the impact on a pumps
efficiency as the gap between the outside of the impeller and casing is larger creating
inefficiencies.

Although a pump curve shows the various duty points that a pump can achieve, operating the
pump in some of the areas of operation can lead to many problems.
Best Efficiency Point (BEP)
As you can see in the illustration across and above pump curve there is a point typically midway
curve known as the Best Efficiency Point which is the most efficient point at which the pump
can be operated at.

As you can see in the below illustration if the pump is operated on the left it can mean low
bearing life, mechanical seal failure and heavy vibration.

If a pump is operated too far left on its curve there is no allowance for extra capacity should
there be miscalculation in system pressures. Too far to the right and there is the risk of cavitation
which can destroy the pump casing and impeller very quickly and cause the liquid to boil. Good
practice is to always have a safety margin maybe 10% towards the left of the duty point to ensure
the pump can operate as required, as a pumps performance can always be reduced, but not
increased.

Positive Displacement Pump Curve

A positive displacement curve is different to that of a centrifugal pump curve as it is usually a
straight line.

This is because a positive displacement pump flow is proportional to rpm and does not decrease
with pressure like a centrifugal pump. A PD pump curve usually has a separate axis detailing
viscosity, where the pump will show a flow against viscosity as per the graph below.
What is a NPSH Pump Curve?
The NPSH pump curve shows the Net Positive Suction Pressure Required (NPSH) in Metres (M)
to deliver the duty point. The NPSH of a centrifugal pump is typically stable on the left side of
the axis, where a pump is producing the highest pressure but lowest flow. After the Best
Efficiency Point the NPSH curve steadily increases before rising sharply at the end of the
performance curve where the pump will cavitate if operated. The NPSH curve is more relevant to
rotary centrifugal pumps and less relevant to positive displacement pumps which are less likely
to operate end of curve and cavitate. In the below curve an NPSH of 3.32M is required to deliver
the required performance.
What is a system curve?
A system curve provides a graphical image of the pump head required to move fluid around the
designed system. The system curve considers the losses of all the required components at various
flows within the system, as well as the static head. A system curve will be plotted on to a pump
curve, and where the two intersect determines the flow and pressure which will be produced in
the system.

What is a pump efficiency curve?

A pump efficiency curve shows the efficiency of a pump across the range of flows and pressures
produced by a pump. On the left hand side of the curve the efficiency will range from 0 to a
maximum of around 85% efficiency before decreasing after approximately mid performance
curve. Ideally a pump should be operated as close as possible to its BEP for maximum
component life, and minimal wear.

Outside of the Best Efficiency Point (BEP) the pumps performance will suffer and if operated
inefficiently can damage itself, leading to its destruction within minutes.

Pump curve vs rpm

Pump curves are shown at full motor speed, but if the speed of the pump is reduced the curve
will reduce. The outer edge of the curve will step inwards towards the axis on all sides meaning a
reduction in both outlet pressure and flow. Reducing a pumps speed is more efficient than
reducing an impeller diameter as the clearances between the impeller tip and casing remain
small. 2 pumps operating at 50% capacity will save more energy than one pump operating at full
capacity.

Pump curve vs power

The power a pump uses to deliver a specific performance varies according to where the pump
operates on its curve. Pumps are often fitted with larger motors than required for the duty point,
to ensure should the pump operate towards the end of its curve it will continue to operate as
required and not trip. As you can see in the below curve on the far left the pump absorbs (uses)
just over 3.5Kw, and at duty point to deliver the flow required a power of 7.09kw is required.
The power absorbed by the pump continues to rise after the duty point, meaning in practice a
pump should be fitted with a motor of at least 7.5kw to cover end of pump curve.

Centrifugal Pump Vs Positive Displacement Pump

Centrifugal Pump Curve PD Pump Curve
Fluids One Fluid Viscosity Several viscosities
Flow Flow Varies significantly. Flow is proportional to RPM,
Particularly if pressure and pump is known to be a
losses are miscalculated. volumetric pump with very
predictable behavior.
RPM One RPM unless multispeed RPM is detailed on the graph.
curve. Flow is proportional to
RPM. Pressure is constant
meaning pump is volumetric
Curve Shape Sloping curve detailing drop Straight line demonstrating
in flow against pressure flow proportional to RPM
with little change to flow
across pressure
Efficiency Small area of curve Efficiency is constant
Efficiency vs Viscosity Efficiency drops significantly Accepts up to 50,000cst.
with viscosity, with a Pump performance increases
handling limit of around with viscosity
300cst
NPSH NPSH increases significantly NPSH remains constant
at end of curve

Important Notes & Assumptions

Curve Basis
Curves are always based on fresh water at 20°C at sea level which may not reflect the
requirements of your application which is why the fluid viscosity and specific gravity are
required to create an accurate representation of what your equipment will achieve.

Viscosity
Viscosity can vary significant with certain fluids such as oils and it is important to ensure the
figure quoted is correct. Many fluids have a viscosity quoted at 20°C or 60°C which can be far
from the actual pumping temperature especially in cooling applications where the pump is
required to work prior to the oil being heated.

Minimum Continuous Safe Flow (MCSF)

The Minimum Continuous Safe Flow is the minimum amount of a flow a centrifugal pump can
do without sustaining issues such as cavitation, or excess wear and is often a figure used to
design operating speeds, and bypass control valves in processes where pumps may be running
continuously such as boiler feed applications, cooling or in lubrication applications.

Motor Pole sizes

Motors on centrifugal pumps revolutions are set by the number of poles in the motor. The more
poles a motor has the slower it will operate at. Increasing the number of poles in a motor can
help pumps to produce more flow at lower pressures, and gain from a reduction in the NPSH
required, suffer from less wear and tear, and utilize a smaller powered motor. If a higher pressure
is required and lower flow pumps will operate at higher RPM to generate the pressures required.

Changing the number of poles in motor is not the only way to change pump speed. Pumps can
also be set at individual rpms if used through an inverter or mechanical variator. Positive
displacement pumps will usually use a gearbox with a pump operating at full motor speed in
order to ensure the pump operates at a set RPM.

Some applications will require a pump to operate for a short amount of time, and others for 24/7
such as in cooling at which point a low motor speed will be chosen. A PD pump may have a 2
pole motor rather than a higher pole due to the starting torque. Care should also be taken as
motors can be listed as having a high RPM but in actual fact the rpm may be rated as less from
the motor. North Ridge Pump curves are specified to the exact RPM of the motor rather than
using a general figure.

Motor Poles RPM at 50hz RPM at 60hz

2 2900rpm 3600rpm
4 1450rpm 1800rpm
6 1000rpm 1200rpm
8 750rpm 900rpm

Pump Design Tolerances - ISO9906 Testing

ISO9906:2010 details the hydraulic performance criteria a rotodynamic pump must adhere to.
There are three levels of acceptance being:

· 1B, 1E and 1U
· 2B and 2U

· 3B

This means that depending on the class used for testing the head can vary between +- 0% to +-
7% and flow between 0% to +-9% which requires careful consideration during pump selection.
This is often why margins are added to requested performance.

Table of Pump Design Tolerances

Variable Symbol Class 1 Tolerance Class 2 Class 3
Tolerance Tolerance

1U 1E 1B
Flow Rate tQ +0% to ± ± 5% ± 8% ± 9%
10% 5%
Pressure tH +0% to 6% ± ± 3% ± 5% ± 7%
3%
Pump η 0% 0% -3% -5% -7%
Efficiency
Pump Power p 10% 4% 4% 8% 9%

Pump curve affinity law

The pump affinity laws are a set of formula which can be used to determine a pumps
performance when a change is made such as speed, or impeller diameter to the produced flow
and pressure with a high degree of accuracy.

There are 3 affinity laws:

1) Flow is proportional to the shaft speed or impeller diameter

As the shaft speed or the impeller diameter is altered, the flow will change by the same amount.
If the speed of a pump is reduced by 20% the flow at the same head will also decrease by 20%.

2) The pressure produced is proportional to the square of shaft speed or

impeller diameter
When the impeller diameter is altered or shaft speed is changed pressure changes proportional to
the square of the change in shaft speed or impeller diameter. If a shafts speed increases by 10%
then pressure at the same flow will increase by 21%
3) Power is proportional to the cube of shaft speed or impeller diameter
If the shaft speed increases by 10%, then due to power being proportional to the cube of shaft
speed the pressure will increase by 33.3%.