Advances in Environment Technologies, Agriculture, Food and Animal Science

The control of variable speed pumps in series operation

DANIELA POPESCU

ADELAIDA MIHAELA DUINEA DENISA RUSINARU

Energy Department - University of Craiova
107 Decebal Bld., 200440-RO, Craiova, ROMANIA
dpopescu@elth.ucv.ro

Abstract: This paper presents a simulation model for the operation of two series pumps, the second being
driven with variable speed. Although this is not usual for this type of configuration that requires generally both
pumps working at the same speed, it seems to be preferred in practice. The model was developed so that to be
able to quickly check the efficiency variable speed drives based on real values, each time more. This can make
possible the choice of other equipments leading to the highest efficiency. The mathematical model was
developed in per units in MATLAB/Simulink environment and can be used for all types of pumps.
Key-words: pump, variable speed drive, series operation, mathematical model, simulation.

1 Introduction

2 Pumps in serial head added

Pump speed control includes both mechanical and

electrical methods of matching the speed of the
pump to the flow/pressure demands of the system.
Adjustable speed drives, multi-speed pumps, and
multiple pump configurations are usually the most
efficient flow control options, especially in systems
that are dominated by friction head. This is because
the amount of fluid energy added by the pumps is
determined directly by the system demand. Pump
speed control is especially appropriate for systems
that are largely dominated by friction head. Pump
speed adjustment is not appropriate for all systems,
however. In applications with high static head,
slowing a pump risks inducing vibrations and
creating performance problems that are similar to
those found when a pump operates against its
shutoff head. For systems in which the static head
represents a large portion of the total head, caution
should be used in deciding whether to use adjustable
speed drives (ASDs). Electrical ASDs include eddy
current cluthes, wound-rotor motor controllers, and
variable frequency drives (VFDs). For many
systems, VFDs offer a means to improve pump
operating efficiency despite changes in operating
conditions [1]. VDFs may offer operating cost
reductions by allowing higher pump operating
efficiency, but the principal savings derive from the
reduction in frictional or bypass flow losses.
Another system benefit of VFDs is a soft start
capability. During startup, most motors experience
in-rush currents that are 5 6 times higher than
normal operating currents. This high current fades
when the motor spins up to normal speed. VDFs
allow the motor to be started with a lower startup
current (usually only about 1.5 times the normal
operating current). This reduces wear on the motor
and its controller.

ISBN: 978-1-61804-188-3

When two (or more) pumps are arranged in serial

their resulting pump performance curve is obtained
by adding their heads at the same flow as indicated
in figure 1.

Fig.1. Pump Characteristic Curve for Two Identical

Centrifugal Pumps [2]
Centrifugal pumps in series are used to overcome
larger system head loss than one pump can handle
alone. For two identical pumps in series the head
will be twice the head of a single pump at the same
flow rate as indicated in point 2. With a constant
flow rate the combined head moves from 1 to 2. In
practice the combined head and flow rate moves
along the system curve to point 3. Point 3 is where
the system operates with both pumps running and
point 1 is where the system operates with one pump
running.
Series operation is frequently used where a larger
pump cannot operate with the NPSH being made
available from the system. A smaller pump is
therefore installed upstream of the larger one to
boost the suction pressure to the larger pump.
It should be noted that in the series operation, the
only essential similarity between the two pumps is

212

Advances in Environment Technologies, Agriculture, Food and Animal Science

that they both must be able to operate at the same

flow rate. The pumps can deliver totally different
levels of head as long as they operate at the same
capacity.

h = a1 n2

+ b1 n
q + c1q 2
2
n
n

(8)

or:

h = a11 2 + b11 q + c11q 2

where: a11 = a1 n2 , b11 = b1 n , c11 = c1 , =

3 Mathematical model
A useful method for comparing characteristics of
pumps at different speeds is to normalize on a
selected operating condition, usually best efficiency
[3]. These curves are applicable to pumps of any
size because absolute magnitudes have been
eliminated.
For this feature is based on the internal pump
characteristic at constant speed in actual units [4]:
(1)
H = A + BQ + CQ 2
Where H is the head, Q is the flow rate and A, B,
and C are constants to be determined from boundary
conditions. By dividing the head H by Hn (the head
of the best efficiency) the pump characteristic is
written as:

H
1
=
A + BQ + CQ 2
Hn Hn

1
A + BQ + CQ 2
Hn
H
where: h =
Hn

h = h0 =

For q = q min =

1
Hn

H min
2
= a11 2 + b11 q min + c11q min
(11)
Hn
Q
For q = q max = max , the maximum h value
Qn

results as:

hmax =

where: a =

(4)

(5)
2
n

BQn
CQ
A
Q
,b =
,c =
,q =
Hn
Hn
Hn
Qn

2
2
(hmin h0 )q min
(hmax h0 )q max
q max q min (q max q min )
(h h0 )qmin (hmax h0 )q max
c11 = min
q max q min (q max q min )

b11 =

The network pipe characteristic in actual units is:

(14)
H r = H s + M RQ 2
where HS is the static head of network and MR is the
strength modulus of pipe network which is
determined as:

2n
[rot/min] is the speed .
60

Following the same reasoning as above, the

value in p.u. is:
(7)
h = a1 2 + b1q + c1 q 2
Consequently by dividing speed by nominal value
results:

ISBN: 978-1-61804-188-3

(12)

a11 = h0

The value in (5) represents the internal

characteristic of pump, at constant speed in per units
(p.u.).
Considering the speed the value in (1) becomes:
H = A1 2 + B1Q + C1Q 2
(6)
where: =

H max
2
= a11 2 + b11 q max + c11q max
Hn

where Qmin, Qmax are the values of minimum and

maximum flow rate, Hmin, Hmax, H0 - the minimum,
the maximum head and shot off head written on
pump.
For =1 (=n) the characteristic of pump
results as:
(13)
h = a11 + b11 q + c11 q 2
where:

or:

h = a + bq + cq 2

Qmin
, the minimum h value
Qn

hmin =

(3)

Q
2 Q
A + BQn

+
CQ
n
2

Q
Q
n
n

(10)

results as:

Following is divided by Qn, therefore the flow

rate at BEP (named here Best Efficiency Point):

h=

H0
, a11 = h0
Hn

where H0 is the shot off head.

(2)

The value in (9) represents the internal

characteristic of pump at some speed in p.u.
The boundary conditions are defined to
determine the coefficients a11, b11, c11.
For q=0, the p.u. pump characteristic results as:

or:

h=

(9)

p
n
8
l
M R = k k + m kj 2 4
dk
k =1
j =1
gd k

213

(15)

Advances in Environment Technologies, Agriculture, Food and Animal Science

where is the Darcy coefficient; - the Weisbach

coefficient; k - the number of pipe network sections;
p the number of hydraulic resistances on a single
section; lk, dk the length, respectively the diameter
of section k.
By dividing (14) by Hn the following value
results for the two pumps operating in series:

For:

P1n P01
Qn
P P02
P2 = P2 n D2 = 2 n
Qn

P1 = P1n D1 =

(16)

p1 = p 01 + d 1 q

(28)
Since the second pump is meant to be driven at
variable speed, its power characteristic can write as:

(17)
2
n

H
M Q
Hr
Q
, hs = s , r = R
,q =
Hn
Hn
Hn
Qn

p 2 = p 02 + d 2 q

p1 =

P
P
P1
P
, p12 = 2 , p 01 = 01 , p 01 = 01 ,
P1n
P2 n
P1n
P1n

d1 =

D1Qn
DQ
Q

,d2 = 2 n , q =
, =
P1n
P2 n
Qn
n

On the other hand, from the affinity laws, the

speed is proportional with the cube of the demanded
flow rate:

Qc nc
=
Qn nn

(30)

or in p.u.:

qd = d

bc = b11 + b12

(31)

4 Simulink model

cc = c11 + c12

For the simulation of the two series pumps operation

the tool Simulink in MATLAB was used.
The following inputs were defined for the model:
shut off heads, H01, H02; minimum heads, Hmin1,
Hmin2; maximum heads, Hmax1, Hmax2; minimum flow
rates, Qmin1, Qmin2; maximum flow rates, Qmax1,
Qmax2; demanded flow rates, Qc; flow rates at BEP,
Qn1, Qn2; heads at BEP, Hn1, Hn2; difference in
height between the discharge of Tr.I pump and the
Tr.I pump suction, HS; strength modulus of pipe
network MR; no-load power losses, P01, P02; rated
powers, Pn1, Pn2; rated speeds, n1, n2.
The model outputs are: output flow rate, qc;
output head, hc; total absorbed power, pc.
The corresponding
model
diagram in
SIMULINK is shown in Figure.2.

In the operating point the following condition

must be fulfilled:
hc = hr
(20)
Therefore:
(21)
a c + bc q + c c q 2 = hs + rq 2
The flow rate is:

qc =

(29)

where:

For the first pump which operates to: =1

(=n) its characteristic can be written as
h1 = a11 + b11 q + c11 q 2 .
The second pump operates to: 1 (n), being
driven at variable speed. Its characteristic is
h2 = a12 2 + b12 q + c12 q 2 .
Coupling characteristic is:
hc = h1 + h2
(18)
Thus:
(19)
hc = a c + bc q + c c q 2
where:

a c = a11 + a12

(27)

p 2 = p 02 + d 2 q

or:

where: hr =

(26)

The equations are written in p.u. as:

Hr Hs M R 2
=
+
Q
Hn Hn Hn
hr = hs + rq

(25)

bc bc2 4(cc r )(a c hs )

2(c c r )

(22)

Note only positive solution.

Power characteristics of the two pumps in
absolute units:
P1 = P01 + D1Q
(23)

P2 = P02 + D2 Q
(24)
where: P1, P2 are absorbed powers by each pump;
P01, P02 - the no-load power losses; D1, D2 - the
coefficients determined by boundary conditions.

ISBN: 978-1-61804-188-3

214

Advances in Environment Technologies, Agriculture, Food and Animal Science

Fig.2. The Simulink model diagram

5 Results
To validate the model an ensemble of the following
equipments was considered [5], with motors
characteristics given in Table 1:
- first pump: WKTA 300/1 (KSB);
- first motor pump: HXR400LC4 (ABB);
- second pump: Omega 250-800 ASCGF
(KSB);
- second motor pump: HXR450LG4 (ABB)

90 210
80
70 200
60
50 190
40
30 180
20
10 60

200

400

600

800 1000 1200 1400

Q
3

Fig.4. Pump characteristics Omega 250-800 ASCGF

H

90 100
80
70 90
60
50 80
40
30 70
20
10 60

Table 1. Motors characteristics

Motor

Un
[kV]

Pn
[kW]

HXR400LC4
HXR450LG4

6
6

355
710

200

400

600

800 1000 1200 1400

96
97

Converter to drive the engine is manufactured by a

company VACON, with depending on loading
yields given in Table 2.

Fig. 3. Pump characteristics WKTA300/1

ISBN: 978-1-61804-188-3

Pn
[%]

cos
0.75
0.75
Pn
Pn
Pn
[%]
96 0.86 0.84
97 0.88 0.86

215

Advances in Environment Technologies, Agriculture, Food and Animal Science

This deviation is also influenced by the fact the

static head of the network is not nil. For an
operation with a demanded flow rate of 0.744 p.u.
the errors between the simulation and experimental
results are of 4.5% for the constant speed drive, and
respectively one of 7.1% for the variable speed
drive.
Comparing the data resulted from simulation,
those based on affinity law and the experimental
ones there can be stated that the proposed model is
valid. It can be used for the analysis of the energy
efficiency of any other series operating pumps.

Table 2. The FCS efficiency

P/Pn

0.2
0.92

0.5
0.96

0.8
0.975

The simulation revealed the curves of the power

consumed by the second pump in p.u. values, as is
given in Fig.6.

References
[1]
***Improving
Pumping
System
Performance. A Sourcebook for Industry,
Hydraulic Institute in cooperation with
Laurence Berkeley National Laboratory and
Resource Dynamics Corporation, Vienna,
January, 1999.
[2]
***www.engineeringtoolbox.com/pumpsparallel-serial-d_636.html.
[3]
Stepanoff, A. J. Centrifugal and Axial Flow
Pumps, 2nd ed., Krieger Publishing,
Malabar, FL, 1957.
[4]
Shields , S., Centrifugal Pumps Academy,
in World Pumps, nr. 418 Iuly 2001.
[5]
Ciontu M., Popescu D., Motocu M.,
Analysis on energy efficiency by replacing
the valve with variable speed drive
condensate pump from E.C. Turceni, The
3rd International Symposium on Electrical
and electronics Engineering, September 1618, 2010, (ISBN 978-1-4244-8407-2, Galai
University press Cod CNCSIS 281), pp
293-297.
[6]
Bonal, J., Entranement vitesse variable
des machines compression des fluides, art.
D.530-1, Edition Technique de lingnieur.
[7]
Dessoudre, M., Moteurs asynchrone
Choix et problmes connexes, art. D.3490,
Edition Technique de lingnieur
[8]
***IEC
61800-2
Adjustable
Speed
Electrical Power Drive Systems, 2004
[9]
Trevor, B., Energy Efficiency in Pumps
Specification, in World Pumps, nr. 415,
April, 2001.
[10]
Shiels, S., Optimizing centrifugal pump
operation, in World Pumps, nr. 412,
January, 2001.

Fig.6. Absorbed power characteristics

for the second pump

6 Conclusions
In this paper a mathematical model was proposed
for the series operation of two different pumps.
The model is based on a real case data acquired
in a revamped thermal power station. This refers to
a two serial pumps installation that was upgraded. A
new solution with pumps drive at variable speed for
flow rate control was analyzed.
Since this solution can be useful for any other
thermal power station, the model was developed in
p.u. and may be therefore applied for any other
pumps type.
The simulation study revealed the bigger is the
flow rate request by using the second pump with
variable speed control, the lower is the absorbed
power by comparison to that of the model with
constant speed control. This decrease is even greater
as the request of flow rate is lower exceeding 80%
for the allowable minimum flow rate. According to
the affinity law model, the power depends on the
cubed speed, and respectively the cube flow rate.
Some deviation errors could be observed between
the simulation data and those obtained by applying
the affinity law model.
This deviations are as higher as the flow rate is
higher: e.g. if the demanded flow rate decreases
down to 0.625 of the nominal flow, the absorbed
power decreases down to 0.379 of the nominal
power, not to 0.244 of this as it would be the
correspondent given according to the affinity law.

ISBN: 978-1-61804-188-3

216