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Basic Principles for the Design of Centrifugal Pump Installations


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18
STERLING FLUID SYSTEMS GROUP
www.sterlingfluidsystems.com
BASIC PRINCIPLES
FOR THE DESIGN
OF CENTRIFUGAL PUMP
INSTALLATIONS

Contents List Page 7


Index Page 376

© Sterling Fluid Systems B.V


Published by:
Sterling SIHI
A Member of the Sterling Fluid Systems Group

We do not make any claim to the completeness of this book. All information is given
based on our many years experience and unless ascribed to a particular reference, the
work is correct to the best of our knowledge and given without any guarantee.

In this book no mention is made of any existing patents, patterns or trademarks. The
omission of any such indication does not infer that any such trade names or
trademarks may be used.

The reproduction of any part of this book in any form is not permitted. All rights are
reserved. Translation, copying and distribution including copying to electronic
storage such as CD-ROM, video disc etc. and input in to electronic media such as
VDU and Internet etc. is not permitted without the written permission of Sterling
Fluid Systems b.v. and could lead to legal proceedings.

7th enlarged and revised edition 2003.


© Sterling Fluid Systems B.V

€70 / US $70

© Sterling Fluid Systems B.V


Foreword
This is the 7th edition of this Pump Book, and since it was first written it has
become an established and respected reference book . It has been completely
reworked and enlarged to include the very latest international and European
standards. In many cases reference is also made to old standards as well as
the new.

This comprehensive edition covers all aspects concerned with the pumping of
liquids and is a dependable reference work in the design and operation of pumps
and pump systems.

In addition it offers both designers and operators a wealth of detail when


considering the whole life costs of a pump installation.

It has been compiled by Sterling SIHI’s most experienced and knowledgeable


engineers, ensuring it’s content should be invaluable to any engineer who is
involved with the pumping of liquids.

Our thanks to all those who assisted in its compilation.

© Sterling Fluid Systems B.V


4

© Sterling Fluid Systems B.V


Centrifugal Pumps
Vacuum Technology
Engineered Systems
Service Support

Manufacturing Programme

Liquid Centrifugal Pumps Vacuum Technology


x Volute Casing Pumps x Liquid Ring Vacuum Pumps
x Chemical Pumps x Liquid Ring Compressors
x Side Channel Pumps x Dry Running Vacuum Pumps
x Multistage Ring Section x Gas Ejectors
x Pitot Tube Pumps
x Sealless Pumps
x Heat Transfer Pumps Engineered Systems
x Self Priming Pumps x Engineered Vacuum Systems
x Sludge Mixers x Engineered Compressor Systems
x Vertical Turbine Pumps x Vacuum Based Membrane Systems
x Filling Systems

Service Support
x Field Service
x In-house Report/Service
x Total Pump Management
x Energy Consultancy

© Sterling Fluid Systems B.V


6

© Sterling Fluid Systems B.V


Contents
Formulae, Notation and Units 10
1 Selection data for centrifugal pumps and installations
1.1 Flowrate 14
1.2 Mass flow rate 15
1.3 Total head 15
1.4 Suction capacity 27
1.5 NPSH for centrifugal pumps 28
1.6 Specific energy 37
1.7 Power, efficiency 38
1.8 Speed and direction of rotation 41
1.9 Specific speed and characteristic type number 42
1.10 Pump selection 45
1.11 Design of the installation and life cycle costs 45

2 Operational performance of centrifugal pumps


2.1 Characteristic curves 49
2.2 Adaptation to varying operating conditions 54
2.3 Effect on the characteristic by the installation of an orifice plate 69
2.4 Operation of centrifugal pumps in branched pipelines 71
2.5 Start up and run down of centrifugal pumps 77
2.6 Minimum and maximum flowrates 82

3 Acceptance tests for centrifugal pumps


3.1 Preliminary remarks 86
3.2 Acceptance tests to DIN EN ISO 9906 86
3.3 Acceptance tests for side channel pumps 95

4 Special information for designing centrifugal pump installations


4.1 Pumping viscous fluids 96
4.2 Design of the pump according to the installation 107
4.3 Design of suction and inlet pipes 110
4.4 Design of the suction chambers for vertical pumps 112
4.5 Priming centrifugal pumps prior to start up 116
4.6 Pumping liquid / gas mixtures 120
4.7 Pressure surges (water hammer) in piping systems 124
4.8 Forces and moments on flanges 128
4.9 Pumping suspended matter 130
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© Sterling Fluid Systems B.V


4.10 Shaft sealing 135
4.11 Leak-free pumps 146
4.12 Pumping liquefied gases 156
4.13 Pumping hot liquids 162

5 Vibration and noise


5.1 Vibration and smooth running 171
5.2 Noise 172
5.3 Noise protection measures 175
5.4 Noise and sound pressure level 187

6 Head losses in pipework and fittings


6.1 Head losses in straight pipework 178
6.2 Head losses in fittings and valves 186

7 Flanges
7.1 Flanges to European and German Standards 193
7.2 Flanges to American standards - ANSI 194
7.3 Flanges to international standards ISO 195
7.4 Test pressure 196

8 Instrumentation for monitoring centrifugal pump installations


8.1 Pressure measurement 197
8.2 Flow measurement 198
8.3 Power requirement measurement 200
8.4 Speed measurement 201
8.5 Temperature measurement 202
8.6 Vibration measurement 203
8.7 Level measurement 203

9 Fundamentals of electrical drives


9.1 Electrical supply 204
9.2 Electric motors 206
9.3 Construction of Electric motors 212
9.4 Installation and operation of Electric motors 216
9.5 Explosion protection 228
9.6 Speed control of electrical drives 234
9.7 Selection tables for 3 phase AC induction motors 238

© Sterling Fluid Systems B.V


10 Water
10.1 Natural water, drinking water and process water 245
10.2 Important parameters for assessing water condition 245
10.3 Analysis of water 251
10.4 Other naturally occuring waters 255
10.5 Wastewater 255
10.6 Treated water in heating systems and steam power plant 256
10.7 Material selection for different types of water 259
10.8 Properties of different types of water 263

11 Materials and material selection


11.1 Materials 264
11.2 Overview of materials 266
11.3 US materials to AISI standards 276
11.4 US materials to ASTM standards 277
11.5 Materials with trade names 278
11.6 Organic materials overview 279
11.7 Fibre reinforced materials 283
11.8 Ceramic materials 284
11.9 Material selection for handling various liquids 285

12 Units
12.1 General 305
12.2 Units and conversion factors 307

13 Tables 329

Subject index 376

© Sterling Fluid Systems B.V


Formulae, Notation and Units
The following is an overview of the most important terms and units which are used in
relation to centrifugal pumps and pump installations.

Notation Terminology Unit Other common


units
A Area, cross sectional area m2 mm2, cm2, dm2
D Diameter m mm
e.g. impellers
pipelines
d Diameter m mm
e.g. shafts, shaft sleeves
orifices
E Energy J kJ
F Power N kN
f Frequency Hz
G Gravitational force (local) N kN
2
g Acceleration due to gravity (local) m/s
H Total head of pump m
J Moment of inertia kg m2
K Unit of speed s–1
k Roughness coefficient of pipes m mm
l Length m mm, cm, dm
M Torque Nm
n Speed s–1 min–1
NPSH Nett positive suction head m
P Power W kW, MW
p Pressure Pa hPa, bar
Q Flowrate m3/s m3/h, L/s
q Massflow kg/s kg/h, t/h
Re Reynolds number dimensionless

10

© Sterling Fluid Systems B.V


Formulae, Notation and Units (continuation)

S Suction capacity m3/s m3/h


T Thermodynamic temperature K
t 1. Temperature Celsius °C
2. Time s min, h, d
U Mean flow velocity m/s
u Tip speed m/s
V Volume m3 dm3, L
v Speed m/s km/h
y Specific energy J/kg m2/s2
z Altitude m
Height above datum
[ Loss Coefficient dimensionless
K Efficiency %
O Coefficient of friction dimensionless
P Dynamic viscosity Pa s mPa s, N s/m²
2
v Kinematic viscosity m /s mm2/s
3
U Density kg/m kg/dm3 kg/L
Z Angular velocity rad/s

Indices
Parameters or measured values are referenced to a specific point or condition by use
of indices.

Index Meaning Example


A Referred to pump installation HA Total head of installation
abs Absolute pabs Absolute pressure
all Allowable nmax all Maximum allowable
speed
amb Ambient pamb Ambient pressure
B Balancing QB Balancing flow

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© Sterling Fluid Systems B.V


Indices (continued)
Index Meaning Example
D Difference, datum level zD Height of NPSH datum
dyn Dynamic Hdyn Dynamic component of
total head
G Guarantee QG Guaranteed flowrate
g Slip vg Slip speed
geo Static Hgeo Static head
gr Referred to pump unit K gr Efficiency of pump unit
int Internal K int Internal efficiency
J Loss HJ Head loss
L Leakage QL Leakage flowrate
M 1. Pressure gauge, manometer p1M Pressure reading at pump
inlet
2. Referred to the fluid in manometer UM Density of fluid in
measurement line manometer measurement line

m Referred to mechanical efficiency h m Mechanical efficiency


max Maximum nmax Maximum speed
min Minimum nmin Minimum speed
mot Referred to the motor Pmot Absorbed power of pump
drive
N Nominal PN mot Nominal motor power
op Operating Qop Operating flowrate
opt Optimum Qopt Flowrate at optimum
efficiency
r Rated Qr Rated flowrate
s 1. Specific ns Specific speed
2. Suction Hs geo Static datum suction head
sch Peak Hsch Total head at peak flowrate
on a characteristic
sp Specific nsp Specific speed
ss Suction specific nss Specific suction number

12

© Sterling Fluid Systems B.V


Indices (continued)
Index Meaning Example
stable Stable Qmin stable Minimum continuous
stable flowrate
stat Static Hstat Static head
T Transmitted MT Transmitted torque
t Total HJt Total head loss of
installation
thermal Thermal Qmin thermal Minimum thermal
flowrate
u Useful Pu Hydraulic performance
v Vapour pv Vapour pressure
w Operating pw Operating pressure
x 1. Referred to any chosen point in the Hx Head at point x
installation
2. Referred to any chosen value Dx Required impeller Ø for a
particular operating point
z Suction (Positive) Hz geo Static suction head (pos.)
0 At flowrate Q = 0 H0 Zero flow head
1 Suction side p1 Pressure in pump suction
1’ Suction side measurement point p1’ Pressure at suction side
measurement point
2 Discharge side p2 Pressure in pump discharge
2’ Discharge side measurement point p2’ Pressure at discharge side
measurement point
3, 4 .... Intermediate point p3 Pressure at intermediate
point
3’, 4’ .... Intermediate measurement point p3’ Pressure at intermediate
measurement point
Note: A hyphen (-) between 2 indices indicates a difference in value at the given
point but does not indicate which is the larger.
Example: z1–2 = Difference between z1 and z2 .
Either z1 – z2 or z2 – z1

13

© Sterling Fluid Systems B.V

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