BELL & GOSSETT BULLETIN NO, TEH-375 2 Manus! 3100 Rovion ¢ PUMP & SYSTEM CURVE DATA for CENTRIFUGAL PUMP SELECTION and APPLICATION PRICE $5.00 FLUID HANDLING I TT eure 7 armen TRAINING & EDUCATION DEPT.TABLE OF CONTENTS PAGE INTRODUCTION 3 DEVELOPING THE PUMP CURVE. 3 EFFECT OF VISCOSITY ON THE PUMP CURVE....... 8 PUMP POWER REQUIREMENTS ...... . 3 PUMP EFFICIENCY 5 PUMP AFFINITY LAWS... sessesasees 6 MANUFACTURERS PUMP SELECTION DATA... 7 PUMP TABLES.. 13 GENERAL PUMP CURVE CHARACTERISTICS ...cscc014 GENERAL DESCRIPTION OF SYSTEM CURVE 14 SYSTEM CURVE FOR CLOSED SYSTEMS....... 4 SYSTEM CURVE FOR OPEN SYSTEMS 16 LIST OF ILLUSTRATIONS & TABLES... a) INDEX,INTRODUCTION ‘This section of the BKG Engineering Design Manual covers centrifugal pump performance curve and system curve data, Other sections provide additional information on the selection and applica tion of centrifugal pumps. It should be noted that ‘example curves used herein are illustrative only and manufacturers’ data should be consulted for specific information. DEVELOPING THE PUMP CURVE Pump performance is shown by means of a plotted curve which relates the flow (gallons per minute) to the pressure head produced (head in feet of fluid.) ‘The pump curve is established by the manufacturer under carefully controlled test conditions, All B&G. pump test curves are plotted from performance data obtained by using standard production pumps selected at random. A typical head capacity curve is illustrated in figure 1 wa ‘TOTAL HEAD IN FEET the impeller. In a manner of speaking, the pump raises each pound of water passing through it to an energy level at its discharge which is higher than that at the suction by the difference in foot head. Energy as foot pound per pound is shortened to foot head by mathematical term cancellation. Since foot head is a simple energy statement, 2 pump curve defined by this term is not affected by water tempera~ ture change. This is because energy, as such, is not affected by temperature change. Likewise, water density has no effect on the pump curve—though density does affect pump power requirements. ‘A pump curve defined by a statement of foot head vs GPM is then a completely generalized curve— independent of fluid temperature and density. This pump curve, although established by 85°F. water tests, will apply (0 40°F. water, 20°F. water or 400°F. water without change. EFFECT OF VISCOSITY ON THE PUMP CURVE A change in liquid viscosity can affect the pump curve, However, the change must be greater than the change in water viscosity from 40°F. to 400°F. before the curve is affected. Thick, viscous fluids will markedly change the curv because of a great in- crease in the viscous shear force of the fluid being, pumped. (see figure 2) Information covering glycols, and heat uansfer oils is provided in another section of the Engineering Design Manual, Increased ‘fluid viscosity will also affect pump power requirements because of the increased “drag” of the fluid within the pump, CAPACITY IN U.S. GALLONS PER MINUTE Figure 1 Typical Bead Capacity Curse ‘The developed pump curve is almost always illus- trated as foot head vs GPM because this gives a general description of pump operation completely tunaffected by water temperature or density. Some pump curves show PSI vs GPM or PSI vs bs,/hr. These ‘curves are not general, but specific, and require definition in terms of water temperature and density PSI curves are sometimes used for boiler feed pump, description but should not be used in selecting pumps: for Heating-Air Conditioning application, The GPM vs foot head capacity curve is general because of the physical characteristics of the centrifugal pump. ‘The centrifugal pump produces energy in the form of foot pounds per pound of water pumped; and dependent on the volume flow rate passing through a WATER # Se int = a 3 a } ETT ncarnseo LK 2 fe 2 ctivtaie 5 CAPACITY IN. U. GALLONS PER MINUTE igure 2— fet of Ineresed Vscoity onthe Pump Curve PUMP POWER REQUIREMENTS A pump curve stated as GPM ys foot head is apower statement. At any point on the curve, the power put into the water (water horse power) is the water energy input rate. This is foot head (foot pound per pound) X GPM (converted to pounds per minute) and expressed as water Horsepower (WHP). GPMX Head Xp. gr. Water HP= = pe A curve illustrating water horsepower in ‘stablished for any specific pump as illu figure 8. \L HEAD IN FEET: : TOTAL CAPACITY IN U.S. GALLONS PER MINUTE Figure 3- Water Horepsser nat Cerve Water horsepower is zero at no delivery and in- creases with increasing flow; illustrating one of the characteristics of the centrifugal pump—power re- quirements generally increase with flow even though hhead decreases. This is a most important point since lead to a motor overload condition. Pump motor overload on the hydronic system must be avoided because water flow must be maintained in order to prevent freeze up, ete. Actual power requirements at the pump shait will be greater than the power absorbed by the pumped water. This is because of friction lossesin the bearings, friction itself and recirculation within the pump. These additional power losses define the total brake horsepower requirement (BHP) at the pump. shaft as illustrated in figure 4. Water horsepower also inereases with fluid density even though the head capacity curveis not changed. ‘This is because at any fixed GPM point more mass (more pounds per minute of fluid) is being pumped at the higher fluid density. If a fluid with twice the density of water were pumped, the required water horsepower would be doubled. (See Figure 5) The effect of fluid density must then be taken into account when evaluating horsepower requirements for fluids other than water water Example A fluid “A”, having a viscosity equal to water but with a specific gravity of 1.5 is to be pumped. A water base curve indicates a need for 8.2 BHP at the pump selection point, Problem: determine actual BHP and size of motor needed, corrected BHP (fluid A) (water) x sp. gr. (fluid A) 3.2X1.5=48 BHP Solution: a 5 HLP, motor is selected. BHP an over pump (asi operning store an | design flow rate) will draw more horsepower and may 2 = t 3 = Hiches aaa 3 5 — = Wale INPUT FOR A 2 SET Tita i 2 ee a; 2 oF MARR = 4 7 east a| lS Bg 5 va = pi pas g 3 OT onl LS CAPACITY IN US, GALLONS PER MINUTE 5 oH + =, SS Ae Pump test data is usually based on a water tempera- CAPACITY IN US. GALLONS PER MINUTE ture of about 85° (specific gravity approximately 1). ite no peop igure 4~Tolal BHP Requiroment Curve peratures, Since the power requirements are based on near maximum water density the curve illustrates,maximum pumping power. Pumping power will reduce slightly as water temperature is increased s because of decreased water density; but this factor is seldom taken into account. HEAD CAPacTY MAX, EFFICIENCY ‘MF HIS POINT HAN PUMP EFFICIENCY Pump efficiency is defined as water horsepower output divided by pump shaft brake horsepower WHP x 100 BAP ‘and is determined on the basis of manufacturers’ tests using calibrated motors. As previously noted B&G: tests are run on production pumps selected at random. ‘The efficiencies illustrated could be in- creased by laboratory type modifications; smoothing of the impeller and internal water passageways. How- ever, this modification would not be representative of production pumps. An efficiency curve is shown plotted with the basic pump curve in fig L erFICIENCY input, Pump efficiency in per cent is: TOTAL HEAD IN FEET % EFFICIENCY CAPACITY. IN. U.S. GALLONS PER MINUTE Figure 5— Pump Efciency Gurve an “CUas Ares 50 \ 50 / 1 $40) Bao z z \ 220: | g 20 = = z Z #20 zx 2 2 10 10 ° ° Too 200. 300 400.500 Too” 200, 300 400500 CAPACITY IN‘U.S: GALLONS PER MIN. | CAPACITY. IN U:S, GALLONS PER MIN. MAXIMUM EFFICIENCY POINTS | MAXIMUM EFFICIENCY POINTS ‘MIDWAY ON PUMP CURVE \ NEAR END OF PUMP CURVE Figure 7 Comparative Effeoney Range —Midoay v= End of Pamp Cire Maximum efficiency occurs ata particular point or _in the area of maximum efficiency. Selection of pumps within a range on the pump curve. Efficiency de- to an efficiency only criteria may, however, be creases as flow either increases or decreases from its. detrimental to both pump and system operation— design point. The maximum efficiency point is de- especially when the maximum efficiency points are pendent on impeller and volute design and indicates _close to the end of the curve. Most hydronic system an area of flow where minimum impeller and volute pumps have their maximum efficiency range about turbulence is encountered. Pumps are often selected midway plus or minus ¥4 of the published pumpcurve. Such pumps are most suitable to hydronic system application. (See Figure 7) Pumps operating at 3450 RPM are not recommend- ‘ed for hydronic system application. ‘This is because of pronounced shifting of the maximum efficiency pumping area to the right on the curve. Noise trans- mission difficulties may also be encountered. Pump efficiency tends to increase with larger pump . This is because bearing and other mechanical and internal hydraulic losses become a smaller pro- portion of required pump shaft BAP. When pump efficiencies are considered by the engineer as a basic «itera for puinp selection, he must closely define the actual point of operation and predict with certainty the pump operational point. Oversized pumps will lead to greatly decreased system pumping efficiencies. PUMP AFFINITY LAWS The pump affinity laws provide methods for approximation of the effects of changed impeller diameters and rotational speeds on the pump curve. “These laws state: 1. Pump GPM capacity varies directly as the speed (RPM) or impeller diameter ratio change. 2. Pump head varies directly as the squate of the speed (RPM) or impeller ratio change. 3. BP varies directly as the cube of the speed TOTAL HEAD’ IN FEET 00 CAPACITY IN U.! (RPM) or impeller diameter ratio change. ‘The relationships of the pump affinity laws can be formulated as follows: Ds (De\? D2) Des ce BEcy n(n a=) a (oy mC, Re\* pn (R8)* p, Speed Qe mae (RY ne ra (RY Where Q= GPM, H=head, P= BHP D=impeller dia, R=RPM Pump affinity laws can be used for resizing impellers ‘on pumps known to be providing excessive system flows. However, system curve analysis methods pro- vide more definite procedures. Pump affinity laws can also be applied w pump selection for speeds different than the illustrated curve RPM base, Examp! A particular piping circuit may have a high flow-low head requirement and a suitable pump cannot be found at normal speeds (1750 RPM). While small pumps in parallel will often provide a solution, it is decided to apply speed reduction to 1150 RPM. Design conditions are 250 GPM @ 20" head. Since snost pump curves are stated to 1750 RPM, the se- 300 me 700 GALLONS PER MINUTE igure U4 1750 REM Universal Prop Curve Colection problem is to restate 250 GPM @ 20" head and at 1150 RPM to equivalent 1750 RPM conditions. Speed Change Rs Cees aus QO New Flow Rate >> 1750 *250= 380 GPM TI50* i ‘err: 250 GPM G10 REM sual o 380 GPM @ 1750 RPM. Speed Change ey Pl end Fn (Re) 1H 180) 29 a6 New Foot Head (1754 Therefore: 20° head @ 1150 RPMis equivalent to-46" @ 1750 RPM. Reference is now made to standard 1750. RPM es for the condition 880 GPM & 46". The sc- lection point appears on the U4B 1750 RPM Universal Pump curve as illustrated in figure 8. peller size is indicated and 6% BHP ately) is required for non-overload pera- tion at 1750 RPM. BEL? requirements at 1150 RPM will be: Speed Change (Rs)? », — py, Power Forma (Ra) PP" 1150) New Power ({759) 05-19 BHP @ 1150 RPM Aselection for 250 GPM at 20’ head is then a U4-B Universal Pump, using a 7%" impeller and 1150 RPM, 2 HP motor. The procedure outlined above can also be followed for pump selection when using 50 cycle motors. The 60 cycle motor operates at %e of 60 cycle speed. The comparative 1750 RPM is then 1750%% or 1450 RPM. Selection procedure is the same as the precedin example; the only difference being substitution of 1450 RPM for the 1150 RPM illustrated. - z a 3 2 TS 2 fas a as 6 Se Noh20 He. e 32 va HP. | ae HP, DRAW. 15 HP, — CAPACITY IN U.S. GALLONS PER MINUTE Figure 9— Impaler Size Capacity Curve MANUFACTURERS PUMP SELECTION DATA ‘The capacity curve for a particular pump volute will vary as a function of inipeller diameter. This permits the manufacturer to. provide a series of pumps, using a single volute design by changing impeller diameters. Figure 9 illustrates a series of such curves, which include pump efficiencies and re- quired motor H.P, draw for the various impeller sizes shown. ‘Quiet operating pump selection curves (B&G Uni- versal) do not include efficiency information — despite relatively high pumping efficiencies. This is because ‘of convietion that the selection basis for these specially designed pumps should be clearly and unmistakably defined as quiet operation. The best selection range for these pumps is indicated by a clear or lightly shaded area. See Figure 10. The best selection range is about the midpoint of the capacity curve plus or minus (sce figure 10). "This is the normal intended area of pump usage and provides for good pump operation. Pumps are often selected, or operate, to the left of this area; in the low flow, high head range. This is often proposed because of the “drift” of the actual operating point to the right of the specified point and due to highly complex variables including pipingpcircuitry system pressure drop and control valve operation. Operation to the left of the midway operating range does notintroduce ‘operating problems—except for heat dissipation and bearing thrust loads when large pumps are used at or near to dead shut-off, It should be noted that two way open-close or modulating type control valves will often cause a shift in the actual pump operating point from a specified “midway” point to almost shut-off Selection of a pump toward the left of the midpoint of the curve does not introduce the possible hazards of a selection made to the right of the midpoint of the curve. Selection to the right of the curve midpoint will not provide a cushion against possible operation beyond the end of the published curve, Operation i this area causes noisy cavitational operation, pos: ble pump damage and reduced flow to the system “end circuits.” ‘A shift in the actual pump operating point to the right of the specified point will occur if circuit flows are left unbalanced, if three way control valves are applied or if improper pressure drop charts are used. ‘A pump selected midway or toward the left of the curve will permit considerable shift to the right be- fore trouble is encountered. The pump selected close to the right end of the curve has no “shift allowance” and operating trouble can occur. The importance of providing shift allowance can only be illustrated after system curve analysis methodsfeces cence eeeeeeeeeeed y TOTAL HEAD IN FEET is, ‘CAPACITY IN U.S: GALLONS Figure 10st Seletion Range TOTAL HEAD IN ‘FEET "0 THE POINT?) | ‘SELECTION (210 GPM. @ 68" HEAD) Ba BO CAPACITY IN. U.S. GALLONS PER MINUTE Figure 11 Motor Selection on Pump Curvehave been explained. Detailed pump selection pro- cedures are covered in another section of the Engi- neering Design Manual. “The manufacturers composite pump curve illus- trates power requirement (pump shaft BHP) in standard motor H.P. increments, The BHP for a specific operating point can be interpolated between the motor ranges shown. Motors can be selected for either non-overload characteristics or “to the point.” On the pump curve illustrated in figure 11; a 5 HLP, motor selection ‘would be “to the point" for the 8/2" impeller eurve at 210 GPM and 68 fi. head. “The “to the point” motor sclection does not pro- vide for pump operating point shift to the right and may lead to motor overload with consequent system flow stoppage and freezeup possibilities. For the example illustrated a 7% H.P. motor selection would be non-overloading over the entire 8¥4" impeller curve range. Use of a 7% H.P. motor for an approximate 5 HP. draw does not appreciably increase total motor power requirements. A comparison iy illustrated in figure 12 for motor power draw between a5 H.P. motor at full load and for a 7% H.P, motor at a5 HLP. load. ‘The “to the point” selection for the pump using the 5 H.P. motor (210 GPM @ 68’ Head) indicates 7s, PUMP ‘CURVE (APPROX. 1780 RP.) TOTAL HEAD IN FEET exactly 5 HP. draw at 1750 RPM operation. When using the 74/2 FLP. motor the power draw willincrease only slightly beyond 5 H.P. As ilustrated in figure 12 the pump curve will shift up slightly because of the RPM increase of the larger motor operating at partial load. The new curve can be plotted in accordance with the pump affinity laws. However, the actual power draw change will be even less than shown be- ‘cause of the higher efficiency of larger motors. The new point of operation for the 7¥2 H.P. motor and pump combination can be determined by application of the system curve to the new pump curve. Because of the negligible change in power draw between a "to the point” motor selection and a non-overloading motor sele y procedure in actual practice. Provision for non- crease actual power draw. Pumps should be selected as non-overloading over the entire pump curve. This characteristic is most important for hydronic system operation, especially when pumps are to be used in parallel or when the pump operating point is relatively indeterminate and subject to shift; as in the normal heating-air con- ditioning application, Motor selection to the operating point frequently results in a smaller motor dan the non-overloading | CAPACITY IN U.S. GALLONS PER MINUTE igure 12—Comparvon of 5 H.P.o8 "Ya Motor Power Drawmotor selection. Thus, the initial cost of the pump- motor combination is less. However, selection “to the point” must be made with careful analysis by system curve methods and all variables must be properly evaluated, ‘The BHP information included on the composite pump curve permits an approximation of pump efficiency. Example @ 210 GPM, 68 foot head and § BHP—the ap- proximate efficiency will be: GPMXFT HD_ 21068 36 ‘The fact that a large motor may be applied for non-overload operation does not affect pump effi ciency since pump shaft BHP usage will remain the same. Care should be taken when applying pump curve 1LP. for an efficiency approximation that the illus- trated H.P. does not include motor service factor. Motor service factor is the motor manufacturers safety factor and “down rates” the actual motor H.P, ability to provide against low voltage operation ete. TOTAL HEAD IN FEET 2 8 105, we P| 10 20°36 40 8 60 70 80 90 ‘On standard open type A.C. motors of 3 H.P, and over a service factor of 1.15 is applied. The service factors increase with decreased H.P, as illustrated in table I. HORSEPOWER ‘SERVICE FACTOR 1/20 1a iz. 14 1/8 14 V6 1.35 aya 135 V3 1.35 2 1.25 1 1.25 12 1.20 2 1.20 38y 15 ‘Standard Open A.C. Motors Only (40°C, Rise) TABLE 1—ELECTRIC MOTOR SERVICE FACTORS BK&G stock Universal and Booster Pumps have motors which provide for non-overload operation for their complete curve range. Pump Curves for 3450 RPM Operation Pump curves are provided for several motor specds. While 1750 RPM operation is recommended for the 100 10 20 130 40 150 160 170 180 130 CAPACITY IN U.S, GALLONS PER MINUTE gure 13~ Pump Curve for 1750 RPM Operation c4 hydronic system, 8450 RPM operation is often used for industrial and some cooling tower applications. The 3450 RPM pumps are not recommended or comfort heating air-conditioning application, because of the possibility of noise transmission into the system. Operation at a higher speed raises dhe pump ca pacity curve. The pump curve efficiencies and brake horsepower draws are established by test and illus: uated in the same manner as for 1750 RPM opera- tion, Figures 18 and 14 show the pump capacity curve comparison for 1750 RPM and 3450 RPM operation using the same volute and impeller diameters. Variable Speed Pumps Variable speed pumps are generally used for domestic water pressure boosting, The variable pres- sure that can be obtained eliminates need for pneu: matic pressure tanks and provides more stable pressure control. The variable speed pump also is being applied with increased frequency to large valve controlled heating air-conditioning systems having a dead end fiow characteristic. The pump maintains stable pressure «lrops across the control valves and reduces operating power draw. A variable speed pump curve is illustrated in figure 15. TOTAL HEAD IN FEET 20536 a0 60 BO 700 126 140 160 180 200 220 240 260 CAPACITY IN U.S. GALLONS PER MINUTE “available from Stock” —Pump Curves Line mounted pumps are usually illustrated as a family of pump curves, These pumps are generally, but not always, powered for non-overloading char acteristics throughout their entire pumping range ‘The pumps are mass produced and immediately available from stock. Their illustration as a family of ‘curves allows simple use of system curve analysis for pump selection. A family of pump curves for line mounted pumps is illustrated in figure 16, Families of pump curves are alo illustrated for quiet operating base mounted integral horsepower pumps designed for hydronic systems. (see figure 17) ‘These pumps are maintained in stock and are avail- able for immediate delivery. Like the line mounted pumps, they are powered to the end of their published curve and can be used without fear of motor over load, Again, this method of illustration permits simple application of system curve analysis—a basic tool used by the engineer in his pump selection. Net Positive Suction Head (NPSH) Curve Net Positive Suction Head (NPSH) is a pump term that has extremely limited usage for closed loop piping circuit application and properly applied cooling tower pumps. Itis pf great importance, how- ever, in open cireuit industrial application where low tel 280. 300 320 igure 14— Pung Curve for 3430 RPM Operationit z a g = z © £ TOTAL HEAD IN FEET 15 TYPICAL RANGE OF PERFORMANCE FOR VARIABLE SPEED PUMP 200 300-400 ‘500 600 CAPACITY IN U.S. GALLONS: PER MINUTE Figure 15 Variable Spat Prnp Carve BAG BOOSTERS 2izi03 was aM HV. We 40 50 60 70 @ 90 100 110 120 130 140 150 160 170 CAPACITY IN U.S. GALLONS PER MINUTE igure 16-—Faily of Pump Curves Ror Line Mounted Pumps aan700) 80| B&G UNIVERSALS 60 40] TOTAL HEAD IN FEET ° oO 200 400-600" 800 1000 4200 1400 1600 CAPACITY IN U.S. GALLONS PER MINUTE Figure 17—Family of Pump Curves For Base Mounied Pumps ' suction pressures are encountered. Pump manu- facturers provide NPSH curves for specific pumps. A. typical NPSH curve is shown in figure 18. NPSH curves are needed because all centrifugal pumps operate at a lower pressure in the impeller eye than the pressure existing at the pump suction flange. The decrease in pressure within the impeller eye is caused by greatly increased water velocity as water centers the working pump parts. The NPSH curve PUMP PERFORMANCE N.P.S.H. REQ. STOTAL HEAD IN FEET CAPACITY: IN-U.S. GALLONS PER MINUTE igure 18 Typical NPSL Required Curve 3 defines the pressure over and above fluid flash point ‘or vaporization pressure which is needed at che pump impeller eye and takes into account decreased pres- sures within the pump. It should be noted that NPSH shown on the pump curve indicates required NPSH and increases with increased flow (increased water velocity). NPSH evaluation is often needed far industrial ‘open system pump application, especially when using volatile fluids. This is because interior pump pressure reduction can cause cavitation and pump damage. Cooling tower pump selection seldom needs NPSH evaluation provided proper system design and instal- lation procedures are followed. Most closed loop heating and air conditioning system pump application does not require NPSH evaluation because it is possible to obtain adequate pump suction pressurization. The only pump selec- tions requiring NPSH evaluation in heating and air conditioning systems are for steam drum pressurized HITW systems or condensate return pumps. PUMP TABLES In addition to pump capacity curves, most manu- facturers provide pump tables, These tables are based ‘on the curves previously discussed but are tabulated to stated foot head intervals and show the GPM ‘capacity and motor horespower requirements for a: number of pumps at this head. A typical selection table for thirty foot head is shown in table 2. PUMP Gem. | wumpex | HP: | FRAME | BASE 40) Ura Ys ca 50 | ULYeA v | v2 | a 60 | UA 1 | we | 2 75 | ura 1 | we | a2 100 | UZA is | vs | 12 125 | uaa us | re | a2 150 | UBTors 2 | v4 | 12 75 | Una 2 | ve | 12 200 | U22a 3 | 23 | 1 225 | usa 3 | 23 | 1 | 250° | ustors 3 | 23 | a3 : 300 | usa 5s | a5 | 13 TABLE 2~ SELECTION TABLE FOR 30'HEAD ‘Tables are often improperly used for pump selec- tion purposes. Pump selection by tables alone cannot be considered as an engineered selection, A table cannot provide the “picture” of operational char- acteristics that are immediately apparent from the pump curve, Selection tables should be used by the engineer only as an index to the pump curve. GENERAL PUMP CURVE CHARACTERISTICS Pump curves are arbitrarily classified as “flat” or “steep.” This refers to the general shape of the head capacity curve as illustrated in figure 19. ‘rete small change in head. ‘This is advantageous in bal ancing multi-cireuit systems, Flat curve pumps should also be selected for systems using vaive control, The flat curve pump offers a more nearly stable pressure drop ratio across the valves as they go to the closed position and decreases control valve “force open” possibilities. ‘The pump curve permits use of system curves as a method of pump selection analysis. The system curve can be used as a tool to provide beter understanding, of pump selection and operation as it affects overall system operation GENERAL DESCRIPTION OF SYSTEM CURVE System curve analysis methods p determination of good pump application. practice. Parallel and serics pump installations require system carve analysis if operating problemsare to be avoided. System curve analysis will help define the operating relationships between the pump, control. valves, piping circuitry and heat transfer elements for hating-air conditioning systems. The analysis can be applied to permicengineered integration of operating variables. The system curve is simply a plot of the change in energy head resulting from 2 flow change ina fixed piping circuit, System curve construction methods differ between open and closed piping circuits, SYSTEM CURVE FOR CLOSED SYSTEMS A typical closed loop piping circuit is shown in Figure 20. TOTAL HEAD IN FEET CAPACITY IN U.S. GALLONS PER MINUTE Figure 19— Flat o Slrp Prop Curve Fla-curve pumps are generally preferred for dlosed circuit systems because of the influence of the ip curve on the system operating components Large changes in capacity can be achieved with a “ BOILER OR CHILLER igure 20--Typical Clase Lacp Piping Spt From the pipe size and design flow rate, a cal- culated energy head pressure drop is determined. It should be particularly noted that system static heightis of no importance in. determining energy head pressure drop. This is because the static heights of the supply and return legs are in balance; the encrgy head required to raise water to the top of the supply riser is balanced by the energy head regain as water flows down the return riser. Example A design flow rate of 200 GPM establishes $0 foot pressure drop in a typical system, This particular point can be plotted on a foot head versus GPM chart as shown in figure 21. What pressure drop would ‘occur were the flow changed to 125 GPM through the piping circuit? Another calculation would indicate that 11.8 fi. of head is needed. The same procedure carried out for 75 GPM flow rate would result in a 42 foot pressure drop. These points can also be plotted on the foot head versus GPM chart as shown in figure 21. Connection of these three points de~ scribes a “system curve.” ‘The system curve isa state- ment of the change in pipe frietion drop with water flow change for a fixed piping circuit. This is a most important working tool for pump application. Es) 5 #40 z 2% SYSTEM CURVE 3 t = 20) Z | 8 10] 0 50 100150 200” 230] CAPACITY IN U.S. GALLONS PER MINUTE igure 21— Spe Curve Cosructon ‘The calculations described above are not needed to establish a system curve. This is because pipe friction drop varies in a mathematical ratio with the change in water flow rates. Head will change as the square of the change in water flow. This relationship is de- scribed below: 2 ha @) Where: Qs— known (design) flow Qe=final flow his=known (design) head ha=final head 13 Application of the above relationship to a slide rule wrovides a method by which the system curve can be uickly established. ‘The preliminary calculations provide the, known head and GPM values. The “known” headl is set on the A or square root seale. ‘The slide is adjusted to this point and the G scale is adjusted to known GPM, immediately below “known” head. For the example stated above; 80 fi. is set on the A scale and 200 GPM on the G scale, This is illustrated in figure 22. "A" (SQUARE ROOT) SCALE—HEAD WY 2 3 4 567001 2 E 2 456789 s6709 “C SCALE- G.P.M. igure 22~Slide Rate Use For Spite Core Calelatons Head and GPM relationships are made immediately available by adjustment of te slide. In this case 80 ft head at 200 GPM arethe known values. A tabulation for foot head requirement at other flowsis illustrated below: 50 PUMP CURVE 5 | E 40 z point oF oPenation | ae a 2 = 20 Lr Zz qio- Ler + eal [at sesrem'cunve Sa 00109 150200 250) CAPACITY IN U.S, GALLONS PER MINUTE Figure 23 —Syuem Curve Pte on Prop Curvegame 1 stanc oisciice fosehaRce Ech 4 pare LESS THAN igure 24 Typical Open System ‘The complete system curve is illustrated in figure 28, as plotted on a pump curve. ‘The operation of this pump on the piping circuit described by this system curve must be at the inter- section of the pump curve with the system curve. This is because of the First Law of Thermodynamies— ENERGY IN MUST EQUAL ENERGY OUT. Energy put into the water by the pump must exactly match the energy lost by water as it flows through the piping circuit. Water flow through the piping circuit must match pump flow. The point of intersection is the only point that can meet this basic engineering law. For the example, the pump will operate at about 210 GPM and 32 ft. head~ providing the specified selection points (200 GPM, 30 ft. head) are true statements of the system flow and pressure drop relationship. ‘The system curve, as constructed above, is con- tinually used in system design and pump applications, SYSTEM CURVE FOR OPEN SYSTEMS In plotting the system curve for an open system the statics of the system must be analyzed in addition to the friction loss. The different static conditions are illustrated in figure 24. A typical cooling tower application is illustrated in figure 25. In this system, the pump is drawing water STATIC SUCTION LIFT PLUS STATIC DISCHARGE HEAD 16 4) [=r 4 STATIC SUCTION HEAD GREATER THAN STATIC DISCHARGE HEAD from the tower sump and discharging it through the condenser to the tower nozzles, at a 10 foot higher elevation than the sump level igure 23 ~Typical Cooling Tower Application ‘Total friction loss (suction & discharge piping, condenser, nozzles, etc.) is 90 foot at a design flow rate of 200 GPM. Using the design point of 30 foot at, 200 GPM, the “slide rule procedure” previously described can be used to determine the change in piping pressure drop fora change in water flow rates.‘This change is shown below: Foot Head 40 ‘The points shown can be used to develop a system carve. This system curve cannot be applied directly to the pump curve and the intersection taken as the accurate pumping point for the open system. A false evaluation using this criteria, but without evaluating the static height of the tower is shown in figure 26. CAPACITY IN US. GALLONS PER MINUTE Figure 26-~Sptem Curve for Open Cicuit—False Operating Point ‘The illustration is False because the pump must also provide the necessary energy to raise water from the tower sump to the spray nozzles. In this case, the pump must raise each pound of water 10 fi. in height, for stated in another way, it must provide 10 ft. of energy head due to the static difference in height Decween the water levels. ‘The static difference of 10 ft. must be added to the piping pressure drop to provide total required head for each of the GPM points previously noted. The revised GPM versus total required head is shown in table 3. om 0} 11s | 165 | 195 |e88"| an5 | 200 Roos o| 10; 20] 25) 30 | 35] 40 | E seoa || 10] 10] 10] 10 | 0] v0 TABLE 3~GPM Vs TOTAL REQUIRED HEAD (COOLING TOWER APPLICATION) 7 ‘The correct procedure for plotting a system curve ‘rcuit shown in figure 2 TOTAL HEAD IW FEET CAPACITY NUS, GALLONS rR MANUTE Figure 27 —Sem Curve for Open Cirewie—True Operating Point ‘The same system curve construction method applies to a pump operating under a snetion lift— and discharging to a tank at a higher elevation. (See Figure 28). 1 hy t stan, ae ggg QR = —— = y= b zane t suerion py -- Figure 28-- Pann Operating Under State Suction ft ‘When the piping pressure drop curve is adjusted for the 10 ft. static head differential between the tanks; the point of inter-section between the system curve and the pump curve will be the point of opera- ic suction lift of 5 fe has no bearing on is only of importance to anti-cavitation ‘operation (NPSH evaluation). The system curve for this circuit operating at 200 GPM and 30’ Head is shown in figure 29. ‘When a pump is used as a booster, to increase water“TOTAL HEAD IN FEET CAPACITY IN US. GALLONS PER MINUTE Figure 29- Sytem Cure for Static Suction Lift flow rates from an elevated tank at its suction to a tank ata lower clevation, a similar analysis. will determine the actual pumping point. (See figure 30). Figure 30-~Puop Used as Booster from am Blevted Tank For the system shown in figure 30 using the design points of 200 GPM at 30 foot piping and valve pres- sure drop the GPM versus total required head for the flow table would appear as shown in table 4. 18 Design| opm 0/115 | 165 | 125 |Pet9"| o15 | 230 Pipe +Valve | 9! 10] 20) 25) 30} 35] 40 Pressure Drop 10/10] -10|—20] -10 |-10|-10 Total Read Heed for |—10/ 0] +10|+15| +20 |+25| +30 Flow TABLE 4—GPM VS TOTAL REQUIRED HEAD. {USING PUMP AS BOOSTER) In this case, an elevated static head at the pump. suction provides energy head for water flow and the pump simply inereases or “boosts” this head. Since the pump suction tank is at a 10 ft. higher elevation than the discharge tank; the pipe friction curve is dropped to a point registered at a minus 10 ft. on the pump curve, The composite curve then appears as shown in figure 31 CAPACITY INU. GALLONS pe MINUTE igure 31— Composite Carve fr Bleated Tank Pomp Booster Installation At will be generally noted that in most cooling tower applications total pump head is usually composed of a high friction loss (piping, valves, condenser, ete.) plus a relatively low static discharge head. Many other ‘open systems have high static head pumping require~ ments as compared with low piping friction loss. Open system pump selection by system curve methods becomes increasingly important as “open” static head energy requirements become a greater portion of the total pump head.LIST OF ILLUSTRATIONS & TABLES FIG, NO. ILLUSTRATIONS PAGE NO. 1 ‘Typical Head Capacity Curve... 2. Effect of Increased Viscosity on the Pump Curve 3. Water Horsepower Input Gurve.. 4 Total BHP Requirement Curve . 5 Water ILP. & Fluid Density Curve... 6 Pump Efficiency Curve vv i 7 Comparative Efficiency Range~ Midway vs 8 USB 1750 RPM Universal Pump Curve. 8 Impeller Size Gapacity Curve .. i 10. Best Selection Range ..e.orse 11 Motor Selection on Pump Curve. 12 Comparison of 5 H.P. vs 7s H.P. Motor Power Draw . 13. Pump Curve for 1750 RPM Operation 14 Pump Curve for 3450 RPM Operation 15. Variable Speed Pump Gurve 16. Family of Pump Curves for Line Mounted Pumps 17 Family of Pump Curves for Base Mounted Pumps 18 Typical NPSH Required Curve. 19 Flat vs Steep Pump Curve. 20. Typical Closed Loop Piping System... 21 System Curve Construction senses 22 Slide Rule Use for System Curve Calculations 23° System Curve Plotted on Pump Curve. 24 Typical Open Systems... 25. ‘Typical Cooling Tower Application. 26 System Ciinve for Open Circuit~False Operating Point... 27 System Curve for Open Circuit~True Operating Point 28 Pump Operating Under Static Suction Lift. 29° System Curve for Static Suction Lift... 30 Pump used as Booster from an Elevated Tank 31 Composite Curve for Elevated Tank Pump Booster Installation, of Pump Curve... TABLES TABLE NO. 1 Electric Motor Service Factors . 2 Selection Table for 30’ Head 3 GPM vs Total Required Head (Cooling Tower Application). 4 GPM vs Total Required Head (Using Pump as Booster) 1”INDEX Affinity Laws for Pumps. Base Mounted Pump Curves Best Selection Range on Pump Curve. BHP and Pump Efficiency. Closed Loop Circuit—Typical Installation .. Gomposite Curve for Elevated Tank Booster. Comparison of 5 HP vs 7¥2 HP Motor... Comparison of 1750 and 3450 RPM Operation Cooling Tower—Typical Application, Density Effect of Fluids Other Than Water Efficiency Curve for Pumps.o..-eeo Energy from Gentrifugal Pumps..c.... False vs True Operating Point First Law of Thermodynamics. Flat and Steep Pump Curves Establishing the Pump Curve GPM vs PSI Pump Curves. Impeller Diameter Change Procedure .. Impeller Size Capacity Curves Line Mounted Pump Curves... Manufacturers Pump Selection Data... Maximum Efficiency Range... Motor Selection “To the Point” Motor Service Factors. Net Positive Suction Head (NPSH) Gurve.. Non-Overloading Pump Selection NPSH Evaluation Open Cizcuit—Typical Installation Positive Static Energy Head. Power Requirements of Pamp .... Pump Curves Available from Stock... Pump Curves for 3450 RPM Operation... Pump Efficiency Definitions... Pump Operating Under Static Suction Lift Pump Tables Use... Pump Used as Booster from an Elevated Tank Selection of Pump at Other Than Shift Allowance Significance. Speed Change Formula. Speed Selection Using Affi Static Suction Lift-System Curve... System Curve Definition System Curve Points—Establishing by Calculation. System Curve Points ~ Establishing by Slide Rule.... System Curve for Open System .. System Curve Plotted on Pump Curve System Statics Description... Variable Speed Pump Curve veces Viscosity and the Pump Curve... Water Density and the Pump Curve.. Water Horsepower (WHP) Formula. FLUID HANDLING TRAINING & EDUCATION DEPT. (Fr FUUI TRANSFER DIVISION ITT