What is the Purpose of Minimum

Flow?
Over the years use of the term “minimum flow” has evolved. Decades ago
industrial centrifugal pump manufacturers quoted a single, relatively low value
for minimum flow intended to prevent users from running their pumps to
destruction. The term “minimum flow” generally meant the lowest continuous
flow the pump was permitted to operate, without reference to duration,
vibration level or other criteria. Today we have minimum flow values for
continuous operation, for intermittent operation and for permissible
temperature rise.

Pump phenomena and minimum flows

The accompanying chart Pump phenomena and minimum flows shows the
relationships among the various off-design pump phenomena and minimum
flow conditions. The head versus rate of flow curve with indicated phenomena
is a variation of S. Gopalakrishnan’s from his well-cited paper titled, “A New
Method for Computing Minimum Flow,” Proceedings of the Fifth International
Pump Users Symposium; Texas A&M University, May 1988, pp. 41-47. As an
aside, I recall Gopal (everyone knew him by that name) had made a local
technical presentation using the now well-known chart, before it was
published. Evidently the chart was copied from a handout of the overhead
slides and was quickly pirated by another, and then others. Copies or variants
of this chart are now found widely in papers and presentations on pumps.

The quoted minimum flow for continuous operation is usually called “Minimum
Continuous Stable Flow” or its more common abbreviation “MCSF.” It is the
flow below which the pump should not be operated continuously. The usual
purpose of MCSF is to achieve satisfactory bearing and seal life; however
MCSF may be based on other considerations. Any of the following factors
may be considered in establishing the MCSF:

 manufacturer’s experience

 rule of thumb

 calculated onset of suction recirculation or discharge recirculation

 radial thrust

 temperature rise

 cavitation erosion intensity

 maximum permissible pressure rise (for system purposes)

 maximum permissible power rise (high specific speed and axial flow
pumps)

 a combination of the above factors or others not listed

For hydrocarbon process industry API 610 specification pumps, the value of
MCSF is normally coincident with the lower flow limit of the “Acceptable
Operating Range” (refer to chart titled “Vibration limits for Allowable Operating
Range and Preferred Operating Range”) where a specified vibration limit is
not to be exceeded.

Vibration limits for Allowable Operating Range and Preferred Operating Range
MCSF is a value that can range from roughly 10% to 80% of Best Efficiency
Point flow depending on pump size and type, operating speed, impeller
suction geometry, liquid density, and other factors. A size 2” (50mm)
discharge single-stage process pump may have an MCSF as low as 10% of
BEP flow. MCSF is often in the range of 30% to 60% of BEP flow for process
pumps with discharge sizes 3” (75 mm) and larger. Large mixed flow vertical
pumps and very high head-per-stage centrifugal pumps may have an MCSF
greater than 60% of BEP flow. Axial flow pumps have a power curve that
rises toward shutoff and minimum flow may be limited by the power rating of
its driver.

On certain high energy pumps the minimum flow is governed by cavitation

erosion damage. Minimum continuous flow for 40,000-hour impeller erosion
life is where the system NPSH Available curve intersects the pump’s NPSH
Required curve, at lower-than-BEP flow.

Intermittent minimum flow, when specified, is usually given as a percentage of

MCSF. On some applications the governing value may be based on
temperature rise. On large high energy pumps the value of intermittent
minimum flow could be, for example, “70% of MCSF and not to exceed 100
hours per year.”

For some applications a thermal minimum flow or “Minimum Continuous

Thermal Flow” is specified based on permissible liquid temperature rise.
MCTF is usually, but not necessarily, lower than MCSF. While a pump
thermal minimum flow is not always specified, the end user can readily
calculate its value based on input mechanical power heating up the liquid.
The limiting temperature rise is based on a safe margin to prevent flashing of
the pumped liquid to vapor, potentially causing pump seizure.

Thermal minimum flow is not normally a concern at pump start-up as long as

the closed discharge valve is set to begin opening right away. If the margin of
system NPSHA above pump NPSHR is minimal, then the temperature rise
conditions at pump start-up should be checked carefully.

A few pump applications, such as a vertical turbine jockey pump for

maintaining pressure in a large fire sprinkler system, can potentially operate
continuously at shutoff while pump suction recirculation mixes with the water
in the sump in which it operates. The sump acts as a heat sink and a minimal
water temperature rise is not a problem. This example is a rare exception to
an almost invariable stricture on operating the pump continuously at shutoff.

The purpose of minimum flow is generally to prevent undue wear and tear or
damage to the pump. In the real environment of a process or utility plant, a
pump is operated at just about any condition demanded by the situation at
hand. Thus there are different pump minimum flows for different purposes.

For an independent evaluation of a pump minimum flow issue, contact an

experienced consulting engineer who can help with your specific application.
Please take a look at our services to see our areas of expertise.
Minimum Flow System

My friend, In this posting we will discuss about the pump recycle systems. The pump shall be
protected from minimum flow, due to the following reasons;

1. Thermal consideration which has effect to the pump efficiency (The efficiency will decrease
significantly at low flow)

2. At low flow, Internal recirculation will be occurred

3. Increase load impeller (both axial and radial)

4. liquid containing a large amount of abrasive particles must flow continuously through the
pump. at low flow, the particles can circulate inside the pump and erode the impeller.

The three types of pump recycle systems which are generally applied are ;

1. Continuous recycle system --> use Orifice

2. Control loop system and --> use Control Valve

3. Automatic recycle system. --> use ARC

My friend, The followings are short guidance to apply those types.

1. ORIFICE

 This system will provide continuous recycle flow whenever pump is running, regardless
of the process demand.
 Typically applied for pump below 50 hp (38kW), or small capacity.
 Don’t forget, you must consider the additional capacity of the pump (the capacity is
included recycle flow)
 For initial estimation, 30% of rated flow can be used as recycle flow basis.
 Take care for high pressure drop condition, is there any flashing? Two phase? Or
vibration? If two phases is occurred, the orifice should be located at the end of the recycle line.
2. CONTROL VALVE
 When the minimum flow is reached, the valve start to open. The flowmeter shall be
located at pump discharge side (installing at suction side will decrease the suction pressure,
decrease NPSHa )
 The flow meter should be located before(upstream the) recycle line connection.
 Be careful with high pressure drop, control valve may be noise and vibration (an orifice
in series with the control valve may be required)p

3. AUTOMATIC RECIRCULATION

 This type is the spring loaded, combined recycle and check valve
 The spring loaded is set at a pressure correspond to minimum flow (based on pump
curve) where the recycle starts to open.
 Check this link for the detail how the ARC valve work.

 No need additional check valve in the discharge system. The ARC provides back flow
protection.
 Take care with pump with high discharge pressure ( while low pressure source) . The orifice may
be required at the recycle line to avoid very big change of momentum

General Guide.

 Recycle line should be routed back to the source (tank or vessel) NOT to pump suction. Bubble of two
phases can be formed during pressure reduction by orifice or control valve. It may be introduced into the
pump.
 Routing to suction line may causes excessive temperature build up in a very short time.
  For 2 x 100% operation, the recycle line can be connected at combined line.
 For 2 x 50 % operation, each pump shall have its own recycle system.

Generally, the recycle system is not shown in the PFD. There are two specific pumps when a recycle system
should be included in the PFD. These are the BFW pump and pump with the high head or capacity. (discharge
pressure > 1000 psig)

That's all I can share this time.

Hopefully this is useful for you..

Wait ..wait..I have a question for you.

Here my simple question.

Let say, 100 gpm liquid shall be transferred via pump to a tank. The recycle is continuous of 30 gpm use orifice.

How you state the pump capacity in the process datasheet?

A. Normal = 100 gpm , Rated = 100 +30 = 130 gpm
B. Normal = 130 gpm, Rated = 130 x 1.1 = 143 gpm
C. Normal = 100 gpm, Rated = 1.1 x 100 + 30 = 140 gpm
hhmm,,,can you explain WHY ? it is simple, isn't ? :D