feature system & pump curves

‘We’re all just a bunch of

pumps and hose’
In this article, Larry Bachus (aka The Pump Guy) explains the different
elements that constitute typical system and pump curves, and emphasizes
the importance of correctly marrying the two in order to obtain optimized
performance and long life from the pump.

I
went to the hardware store the Too many industrial pumps are the discharge pipes and ends where
other day to buy a half-inch drill problematic, eat bearings and seals the pump loses control of the liquid
bit. I paid US$8.00 cash and left and spend too much time in the (usually another tank or vessel but it
the store. As I was driving home I maintenance bay. Because the pump may be something else).
realized that I really didn’t want the must respond to the needs of the
drill bit. I didn’t want to own or pay for system, the solution to the problem All systems contain four elements or
that drill bit. I really needed a half- lies in the system. The system controls requirements that the pump must
inch hole. Why wouldn’t they sell me the pump. The pump is the slave to complete or overcome. Some of these
the half-inch hole? the system. elements may be nil or even negative.
Let’s consider each element.
This is the problem with pump curves So, in this Pump Guy installment we’ll
and system curves. All too often, we look at mating the pump to the
start with the pump and put it into a system. To do this, we develop the
Elevation
pumping system. Maybe it works and system curve first. Then we’ll mate the
maybe it doesn’t. We really need to pump curve to the system curve. One element is the elevation. If there
start with the pumping system and is an elevation change from the
select or buy a pump that properly suction source to the discharge
mates to the system. But, for some Starting with the destination, then this is one of the
reason we often do things backwards. system… pump’s duties. This elevation change
I’m just as guilty as others in the is called the static head (Hs). If the
industry. To begin, there’s a language problem pump is elevating the liquid 60 ft
to overcome. The problem dates back (20 m) that is the static head.
When I was in active maintenance, I’d to the beginning of recorded time.
call the local pump supply house and Ancient civilizations moved fresh Circulating pumps and closed-loop
inquire about their pump model that water (for drinking, bathing and pumps have no static head because the
compared to the problematic pump irrigation) through aqueducts and vessel being drained is the vessel being
model I had. You see, what I didn’t soon learned that the water’s force filled by the pump. There is no
know was that my pump was (pressure) was a function of its elevation change. Sometimes a pump
problematic because it was poorly elevation. (Also, they didn’t have can pump downhill. Consider an
mated to its system. And buying pressure gauges and other industrial boiler where the feed-water
another brand of pump that compares instrumentation in those days.) So pump drains the DA (deaerator) tank
favourably with my problematic pump today, pump people (pump and pushes the water into the boiler.
meant I was only buying more manufacturers, reps and salesmen) use Often the liquid level in the DA tank
problems and multiplying my parts the term ‘head’ in feet or metres to is higher than the liquid level in the
inventory. I should have started with express fluid force. Process people boiler. Let’s say the DA tank is 30 ft
the system. (production engineers, operators and (10 m) above the pump’s centreline,
mechanics) use the term ‘pressure’ and the liquid level in the boiler is 12
Many a pump salesman will open a measured in psi or kg/cm2 to express ft (4 m) above the pump’s centreline.
sales pitch with a customer by fluid force. A simple mathematical In essence, we’re pumping downhill.
inquiring about the size of the pump to manipulation incorporating a In this case the static head is a
be replaced. The customer says his conversion factor and the fluid’s negative 18 ft (6 m).
pump is a 3 x 4 x 10 end-suction specific gravity converts one into the
centrifugal pump and the salesman other.
says he has the exact replacement
Pressure
pump that will fit into the pipe and Now, we can talk about the system.
couple to the motor with no The system begins at the tank, vessel Another element is the pressure. If
modifications. Actually, the salesman or source to be drained, through the there is a pressure differential from
should start with the system. suction pipes to the pump, back into the suction source (the vessel being

38 0262 1762/05 © 2005 Elsevier Ltd. All rights reserved WORLD PUMPS June 2005
 feature system & pump curves

drained) to the destination (the vessel friction or resistance between the atmospheric vessel. The discharge
being filled) then this is another duty pumped liquid and the internal walls tank is closed and pressurized at 10 psi.
to be completed by the pump. This is of the pipes and fittings. This is called The elevation change is 50 ft from the
called pressure head (Hp). The the friction head (Hf). level in the suction vessel up to the
pressure head is positive if the level in the elevated pressurized
pressure at the suction source is lower discharge tank. Our imaginary system
than the pressure at the discharge has 300 ft of 6 inch steel pipe with
Total dynamic head
destination. assorted gate valves, a globe valve, two
The sum of these four factors is called check valves, a strainer, a heat
Re-circulation pumping and closed- the total dynamic head (TDH) of the exchanger, and numerous pipe elbows
loop pumping have no pressure head system. They can be plotted on a graph and other fittings. Let’s begin
because the pressure at the suction that looks like the old elementary developing the system curve.
source is the pressure at the discharge school mathematical ‘x-y graph’.
destination. And, although not Remember the x-y graph (Figure 1)? Because the elevation change is 50 ft,
common, the pressure head may be then our static head (Hs) is 50 ft. We
negative if the pressure at the In the world of pumps the x-y graph is begin at zero elevation and plot an
discharge destination is lower than the called the H-Q graph. ‘H’ represents imaginary ‘T’ in blue, as shown in
pressure at the suction source. The elevation or head in feet or metres; ‘Q’ Figure 3.
pressure differential is converted into is flow in gpm or some metric
feet or metres. equivalent like litres/min or m3/s If the elevation should change, then
(Figure 2). the plotted Hs will rise or fall with the
change. The change could be a
seasonal event, or even tied to
Resistance
Developing the production schedules. For example, if
Next, there is resistance to fluid flow system curve the Hs is 30 ft at the beginning of an
that drags down or reduces the operation and 60 ft at the end of the
pump’s ability to meet the system’s Let’s develop an imaginary pumping operation then it would be plotted as
requirements. The resistance is system and plot the elements onto the shown in Figure 4.
composed of two factors. One of system curve. Ready?
those factors is the energy lost due to As given, we’re pumping water, the
the velocity of the fluid. This is called Our imaginary pumping system suction vessel is atmospheric and the
the velocity head (Hv). Another requires that we pump cold water at discharge tank is sealed and
factor is the energy lost due to 600 gpm. The suction vessel is an open pressurized at 10 psig. Therefore our

Figure 1. Some basic x–y plots. Figure 2. The pump graph coordinates: H versus Q. Figure 3. Introducing the static head.

Figure 4. Hs may vary over time. Figure 5. Adding the pressure head. Figure 6. The resistance curve.

WORLD PUMPS June 2005 www.worldpumps.com 39

 feature system & pump curves

pressure head (Hp) is 23 ft. The Hp is And, as I mentioned before with we see all four elements superimposed
added to and stacked on top of the Hs. fluctuating elevations and pressures, if onto a pumping system.
It is plotted with an imaginary green the resistance should change
oval, as seen in Figure 5. (throttling or relaxing a valve,
changing a filter) then the resistance
If the pressure differential across the curve will move as in Figure 7. The pump curve
system should change then the
plotted Hp will rise or fall with the So, the precise profile of the ‘Hv + Hf’ Now let’s consider the pump curve. A
change, just as with a fluctuating curve is somewhat elusive. However, pump can push a liquid up into a
static head. the ‘Hv + Hf’ curve can be accurately vertical tube to a point where the
measured and profiled at any moment liquid’s weight is the same as the
Next, we deal with the resistance (Hv under any condition with pressure energy produced by the pump’s driver.
and Hf) in the pipes and fittings. The gauges. We cover this thoroughly in It’s a point where all of the energy of
resistance only exists when the system my lectures and book. (See, we’re all the driver (motor) is invested into
is running. If we don’t consider these just pumps and hose!!) pure elevation. This point is called
factors and design this energy into the the ‘shut-off head’ (Figure 10).
pump, then the pump will be For our imaginary system, let’s say that Maintenance people often use the
inadequate for the service. The Hv and the resistance curve rises 21 ft for a term ‘deadhead’ to express this point.
the Hf work in concert. There can be TDH of 94 ft at 600 gpm. The 94 ft is It is a point on the pump curve that
no friction losses if there is no velocity composed of 50 ft Hs + 23 ft Hp + 21 ft represents maximum elevation at
in the pipes. So, these energies are nil Hv & Hf = 94 ft TDH. We would want zero flow.
at 0 gpm of flow. They increase as flow a pump with best efficiency
increases. The Affinity Laws state that coordinates of 94 ft at 600 gpm. So, A pump running at shut-off head,
head changes with the square of the when you see a system curve, it will when rotated on its axis or centreline
change in the flow. So the profile of usually look like the sole arc in as seen in Figure 11, will trace the H-
the resistance curve (Hv + Hf), will Figure 8. Q curve. Any elevation in feet or
begin at 0 gpm at the sum of Hs and metres will coincide with a flow in
Hp, and rise with the increase in flow That arc represents the Hs + Hp + Hv gpm or m3/s.
approximately like the ‘x2 = y’ curve + Hf, the four elements of every
from the first graph. The resistance system that we call the total dynamic A pump is always somewhere on its
curve is shown in red (Figure 6). head (TDH) of the system. In Figure 9 curve, from maximum head at zero

Figure 7. The effect of a change in resistance. Figure 8. The complete curve for our imaginary Figure 9. The four elements of the total head
system. (TDH) as seen in the pumping system.(From Ref. 1.)

Figure 10. The pump’s shut-off head. Figure 11. Plotting or tracing the pump Figure 12. The efficiency curve.
performance curve. (From Ref. 1.)

40 www.worldpumps.com WORLD PUMPS June 2005

 feature system & pump curves

Figure 13. The BEP and efficiency expressed as Figure 14. Increased resistance moves the pump’s Figure 15. Relaxed resistance moves the pump’s
iso-ellipses. duty point to the left of the best efficiency zone. duty point to the right of the best efficiency zone.

flow, to a point that represents control. The lack of control becomes you’re pumping at 0 gpm (or zero
maximum flow at zero head. I’ve never problem number one. In that case, the production), then the total efficiency
really understood why some people use Pump Guy says, ‘Solve problem is also at 0%. Also, you’d be at 0%
the term, ‘pumping off the curve’. You number one and problem number two efficiency at maximum flow at zero
can’t be off the curve unless something will disappear’. This is something I head. So, as flow increases, the
(like the motor speed, the wear band learned from my old boss ‘L&N’, at efficiency rises to a certain point of
tolerance or other critical tolerance, Republic Steel in Birmingham where I best efficiency (BEP). Then, the
the liquid’s viscosity, temperature or used to work as a young buck. efficiency begins falling again back to
the impeller diameter) is out of 0% at zero head (Figure 12).
control. When you hear someone say The pump’s total efficiency is a
his pump is running ‘off the curve’, combination of the mechanical, Most pump companies prefer to show
he’s really saying something is out of volumetric and hydraulic efficiency. If the efficiencies as concentric iso-arcs

WORLD PUMPS June 2005 www.worldpumps.com 41

 feature system & pump curves

on the H-Q curve (Figure 13). They high flow. The pump will vibrate. smudged line, as though drawn with
do this because it shows better when These vibrations stress the bearings chalk or a marker pen. But basically,
mated with the system curve. The and mechanical seal. Again, you can that pump should be somewhere on its
pump will always run at the expect premature bearing and seal curve. If the system’s head and flow
intersection of the pump curve and failure. The shaft will deflect and you coordinates are not on the pump’s
the system curve. Ideally, this point of can expect high energy spikes as tight curve, then this is problem number
intersection should fall within the tolerances inside the pump bind and one and you must investigate and
pump’s best efficiency zone. The best scrape. The zone to the right of the resolve this. Ask why the system’s
efficiency zone on the pump curve is pump’s best efficiency is where coordinates don’t coincide with the
fixed. The system curve is the curve excessive horsepower is consumed. pump’s performance coordinates?
that floats and moves as levels, This can overload the electric motor
pressures and resistances fluctuate and or trip a breaker. Also, this zone is Hopefully, the system’s head and flow
migrate through their range. As where the pump’s NPSHr will coordinates will coincide with the
resistance increases, the system curve probably rise above the system’s pump’s best efficiency coordinates on
moves to the left of the best efficiency NPSHa and the pump is likely to go the performance curve. If the head
zone on the pump curve (Figure 14). into cavitation. Cavitation will and flow coordinates are too far to the
definitely cause premature failure of left or right of the pump’s best
You can expect energy to be stored in the pump, its bearings and seal. efficiency coordinates, then take
the pump. This means high head and measures to tighten or relax the
low flow, as we can see on the graph. The operator or process engineer can system’s resistance. You may also
The pump will vibrate. These observe the pump running to the right consider ways to manipulate the static
vibrations stress the bearings and of the best efficiency zone. The head and/or pressure head of the
mechanical seal. You can expect short differential head will be too low as system to achieve your goals.
bearing and seal life. The shaft will read on pressure gauges and the flow
deflect. This means that tight will be too high as seen on a Increasing the resistance to move the
tolerances inside the pump will bind flowmeter. When the operator sees the pump towards the left on its curve
and scrape, which causes severe energy pump running to the right of the best should be rather easy. Throttle a
spikes and further stresses the bearings efficiency zone, he needs to increase control valve on the discharge line.
and seal. And, it will generate and the resistance on the system (throttle Relaxing the system resistance to
store heat inside the pump. All stored a control valve for example) and move move the pump towards the right on
energy is converted into BTUs (a BTU the pump’s duty point into the sweet its curve could be as easy as opening a
is the energy to raise the temperature zone of pump performance. throttled control valve on the
of 1 lb of water by 1°F). In simple terms discharge line, installing a new clean
it means that, even if you are throttling Where on the filter screen, or cleaning a discharge
your cold-water pump, you can boil curve…? strainer. But sometimes it’s not so easy.
that water inside the pump while Then you’re gonna have to come to
you’re on your lunch break. Now, I frequently hear this question - ‘Larry, one of my classes, read my book, or
what’s that gonna do to the O-rings how do I know where my pump is invite me to come into your plant.
inside your mechanical seal? running on its curve?’ The answer is (We’re all just a bunch of pumps and
simple. Go get the pump curve. Install hose!!!)
The operator or process engineer can a suction and discharge pressure gauge
observe the pump running to the left of on the pump. Be sure the gauges are Keep this article and store this
the best efficiency zone. The calibrated, accurate and adequate for magazine where you can find it
differential head will be too high as the service. Use compound gauges if quickly. It’s your cheat sheet of useful
read on the pressure gauges, and the you suspect or know that the suction is pump information. ■
flow will be too low as seen on a in vacuum. Start the pump and let it
flowmeter. This is not rocket science. run for a moment in its system. Take Reference
When the operator sees the pump your differential pressure gauge
running to the left of the best efficiency readings and convert to head. (Maybe [1] Larry Bachus and Angel Custodio,
zone, he needs to relax the resistance you can confirm with a flowmeter if you Know and Understand Centrifugal
on the system (install a new filter, or have one installed.) This is where your Pumps, Elsevier (2003) [ISBN:
open a control valve) to move the pump is on its curve. Isn’t that simple? 1856174093].
pump’s duty point into the sweet zone
of the pump. It really is this simple. A word of caution: the printed pump CONTACT
The Pump Guy is Larry Bachus, a pump
performance curve will have pencil consultant, lecturer and inventor, based
Likewise, relaxed system resistance thin lines and curves on the printed in Nashville, TN. He’s a member of
will shift the pump’s duty point to the graph. If the pump is old or has been ASME, and lectures in English or
Spanish. You can contact him at: tel:
right of the pump’s best efficiency zone installed and running for a few years, +1-615-361-7295; fax: +1-615-366-0040;
(Figure 15). This means low head and those skinny lines may actually be a e-mail: [email protected]

42 www.worldpumps.com WORLD PUMPS June 2005