1-Pump Curves - ABS Sulzar PDF

Understanding Pump Curves Sulzer Pumps
Presenter: Michael Stroh – Application & Project Engineer, Sulzer Pumps

June 4th, 2015
OWEA-S: Understanding Pump Curves
The Heart of Your Process

The Static Head is the total vertical

distance that the liquid must be
pumped.
The Static Head is measured from
the starting water level surface to
Head the discharge water level surface.
The Static Head is normally
expressed in “Feet” in the
wastewater industry, meaning feet
of water column.
Static Head
Flow
Customer presentation | May 2012 Copyright © Sulzer Pumps | Slide 2
The Dynamic Head is determined by

analyzing the losses in the entire
piping system at various flow rates.
The losses are based on the
configuration of the piping system.
Head System Curve All pipe and fittings through which
the water flows must be taken into
account.
The Dynamic Head of a system is

computed for multiple flow rates,
Dynamic Head and plotted along with the Static
Head to produce a System Head
Curve or simply System Curve.
Static Head
Flow
The Design Flow is determined by

the pumping requirements of the
station.
The Design Head is determined
from the System Curve. The
Head System Curve intersection point of the Design
Flow and the System Curve
provides the Design Head.
Design The whole purpose of the System

Curve its to provide the Total Head
Head for a particular system, at any flow
Dynamic Head rate.
Static Head
Design Flow
Customer presentation | May 2012 Copyright © Sulzer Pumps | Slide 4 Flow
The Pump Curve is then plotted on

the same graph as the System
Curve.
The intersection point of the Pump
Curve and the System Curve
Head System Curve defines the Flow and Head at which
the pump will operate in this
particular system.
The pump will always runs at this

Design intersection point. It is physically
Head impossible for the pump to operate
at any other point.
Dynamic Head
Pump Curve
Static Head
Design Flow
Most pump stations actually have a

System Curve that continuously
changes during the pumping cycle.
System Curves This change results from changing
static head while the pump is
Head emptying the wet well.
The full range of possible System

Curves are normally represented by
two curves, one at each extreme of
the possible static head.
Low WW Level Static Head
High WW Level Static Head
Flow
When the Pump Curve is added to

the graph, the range of possible
operating points during a pumping
cycle can be seen.
System Curves
The pump will operate the higher
Head flow, lower head point at the
beginning of the pumping cycle.
The pump will operate at the higher

head, lower flow point at the end of
the pumping cycle.
Low WW Level Static Head
High WW Level Static Head
Flow
Most commonly however a single

system curve is provided, and we
select the pump with the
understanding that it may run a little
left or right of the given intersection
point.
Head
Design
Head
Design Flow
An Actual Pump Performance Curve (XFP 301M) Sulzer Pumps
H / ft H / psi
150
64
145
140 60
135 An actual pump
130 56
125
PE
1 04
0 /6 curve for a 12”
120 52
115 pump with a
110 48
105
44
450mm diameter
100
95
40
impeller,
90
85 36
showing Q-H,
81.6%
80
75 32
P2, and
70
65 28 Hydraulic
60
55 24 Efficiency.
50
45 20
40
35 16
Head
P₂ / hp
125
120
115
110
105
100
95
90
85
80
Shaf t pow er P2
75
η/%
70
60
50
40
30
20
10
Hydraulic ef f iciency
0
0 400 800 1200 1600 2000 2400 2800 3200 3600 4000 4400 4800 5200 5600 6000 6400 6800 7200 7600 Q / US g.p.m.

H / ft H / psi
150
64
145
140 60
135
130 PE 56
125 1 04
0 /6
120 52
115
48
A duty point of
110
105
44
4500 gpm at 80
100
95
40
feet (40 feet
90
85
36
static head) has
80 80.1%
75 A1 32 been added.
70
65 28
60
55 24
50
45 20
40
16
35
Head
30
P₂ / hp
125
120
115
110
105
100
95
90
85
80
Shaf t pow er P2
75
η/%
70
60
50
40
30
20
10
Hydraulic ef f iciency
0
0 400 800 1200 1600 2000 2400 2800 3200 3600 4000 4400 4800 5200 5600 6000 6400 6800 7200 7600 Q / US g.p.m.

H / ft H / psi
150
64
145
140 60
135 Because the
130 56
125
PE
1 04
0 /6
impeller is
120 52
115 oversized for
110 48
105 the duty point,
100 44
95
40
the actual flow
90
85 83.74 ft 36
and head will be
80 80.1%
75 A1 32
4712 gpm at
70
65 28 83.7 feet… the
60
55 24 intersection
50
45 20 point between
40
35
Head
16 the pump curve
30
P₂ / hp and system
125 124.9 hp
120
curve.
115
110
105
100
95
90
85
80
Shaf t pow er P2
75
η/%
79.62 %
70
60
50
40
30
20
10
4712 US g.p.m. Hydraulic ef f iciency
0
0 400 800 1200 1600 2000 2400 2800 3200 3600 4000 4400 4800 5200 5600 6000 6400 6800 7200 7600 Q / US g.p.m.

H / ft H / psi
145
140 60
135
130 56 Trimming the
125 PE
120 1 04
0 /6 52 impeller to 440
115
110 48 mm shifts the
105
100 44 performance
95
90
40 curve down so
85
80 80.01 ft
36
that it intersects
75 A1 79.3% 32
70 the system
65 28
60
curve at the duty
55 24
50
point.
45 20
40
16
35
30 Head
12
P₂ / hp
115 115.3 hp
110
105
100
95
90
85
80
75
Shaf t pow er P2
70
η/%
78.65 %
70
60
50
40
30
20
10
0
0 400 800 1200 1600 2000 2400 2800 3200 3600 4000 4400 4800 5200 5600 6000 6400 6800 7200 7600 Q / US g.p.m.
H / ft H / psi
145
140 60
135 For most
130 56
125 PE
1 04
wastewater
120 0 /6 52
115 pumps, the flow
110 48
105
44
limits for
100
95
40
smooth reliable
90
85
36
operation is
80 80.01 ft
75 A1 79.3% 32
from 50% of
70
65 28
BEP flow to
60
55 24
125% of BEP
50
45 20 flow.
40
16
35
30 Head
12
P₂ / hp
115 115.3 hp
110
105
100
95
90
85
80
75
Shaf t pow er P2
70
η/%
78.65 %
70
60
50
40
30
20
10
0
0 400 800 1200 1600 2000 2400 2800 3200 3600 4000 4400 4800 5200 5600 6000 6400 6800 7200 7600 Q / US g.p.m.
Sulzer Pumps
Summary
 The System Curve is a combination of static and dynamic head.
 The static component is based on the vertical distance that the

liquid must be pumped (change in elevation)
 The dynamic component is based on pipe and fitting size, quantity,
and interior roughness of the material.
 It provides a means of selecting pumps by predicting the Total
Head at any flow rate.
 The pump always operates at the head and flow corresponding to the
intersection of the System Curve and the Pump Curve
 When selecting wastewater pumps, the rule of thumb is stay in the
range of 50%-125% of BEP flow. Going outside this range is possible,
but more detailed analysis of the application is necessary.

Understanding VFD Curves Sulzer Pumps

Primary Benefits of Variable Speed Pumping
There are three primary reasons to use a VFD to control pump speeds:
 Control the output of the pump for process reasons (flow or pressure)
 Reduce energy consumption
 Manage starting current
Secondary reasons to use a VFD can include:

 Manage water hammer
 Improve Power Factor
 Precision control of wet well levels
 Managing stations with wet wells that are too small

Affinity Laws
The Affinity Laws predict the Q1 n1

performance of a centrifugal 
pump at differing speeds Q2 n2
 The change is flow is proportional to
2
the change in speed
H1 n
 The change is head is proportional  1
2
to the square of the change in speed
H2 n 2
 The change in power is proportional
to the cube of the change in speed 3
P1 n
Q = flow  1
3
H = head pressure
P = power P2 n2
Affinity Laws
Since we don’t know the exact speed the submersible

pump is turning at any VFD output frequency, it’s common
to substitute the frequency ratio for the speed ratio:
n1 F1 1780rpm 60 Hz
 
n2 F2 1483rpm 50 Hz
n = rotational speed
F = output frequency of the VFD

Calculating Using the Affinity Laws
Therefore, for a pump delivering 2000gpm at 100feet, with

a BHP of 67hp, reducing the speed from 60 Hz to 50 Hz:
60 Hz 2000 gpm

50 Hz 1667 gpm
2
60 Hz 100 ft
2

50 Hz 69.4 ft
Q = flow
60 Hz 3 67hp
H = head pressure
P = power 3

50 Hz 38.8hp
Calculating Using the Affinity Laws
Reducing the frequency (and rotational speed) from 60Hz

to 50 Hz, or about 16.7% results in:
 A flow reduction of 16.7% to 1667 gpm
 A head reduction of 30.6% to 69.4 feet
 A power reduction of 42.1% to 38.8 hp
Of course the pump will not necessarily run at this new flow and
head. The actual new operating point depends on where the system
curve intersects with the reduced speed pump curve.

Example pump, 8” discharge, 4

pole, 115 HP, full speed curve

Reduced speed curves are

parallel to the full speed
curve, and follow the
affinity laws
Flow reduction is directly

proportional to the speed
reduction
Head reduction is
proportional to the square
of the speed reduction
Reduced speed curves

shown in 5 Hz increments

Lines of constant efficiency

added to the curve

Example system curve

added
Full speed duty point is

3600gpm at 95 feet, with
a 30 foot static head
Pump performance at any

speed can be determined
by the intersection point
of the system curve and
appropriate reduced
speed pump curve

The same pump with a

slightly different system
curve
Full speed duty point is

still 3600gpm at 95 feet,
but now with an 85 foot
static head

First Rule of Thumb
First rule of thumb:

Applications where the static head is greater than 50% of the
total head are not usually good applications for VFD
variable speed pumping. This is because:
 Since the system curve is very flat, the pump efficiency at the
reduced speed operating point falls off rapidly. The opportunity for
energy savings at reduced speed is minimal.
 Since the system curve is very flat, there is very little useable
speed reduction range.
 Pump rotational speed at reduced speed, lower flow conditions
remains very high, resulting in high energy recirculation
cavitation, which can damage the pump.

10” pump selection with 25

ft static head, 6 pole 115hp
motor


motor
Useable speed
adjustment range down to Hydraulic efficiency at
below 30 Hz (about 800 full speed duty point,
gpm) 75%
Efficiency increases as the

pump is slowed down, to a
max of 80.4% at 2100 gpm,
then begins to fall
Efficiency falls to 65% at

800 gpm


motor


motor
Useable speed
adjustment range down to Hydraulic efficiency at
about 42 Hz (about 1100 full speed duty point,
gpm) 75%
Efficiency increases as the

pump is slowed down, to a
max of 80.4% at 2800 gpm,
then begins to fall
Efficiency falls to 60% at

1100 gpm

Second Rule of Thumb
Second rule of thumb:

For variable speed applications, select pumps with the full
speed operating point to the right of BEP whenever
possible.
 Selecting to the right of BEP improves efficiency at reduced
speed since the intersection point with the system curve moves
toward BEP when slowing down.
 Variable speed applications often allow the use of smaller, less
expensive pumps.
 Smaller pumps and selections right of BEP provide the best
opportunity for energy savings at reduced speed (where the
pumps run most of the time).
 Check NPSH margin for all selections, especially when selecting
to the right of BEP!

Establishing Minimum Speeds
The minimum speed the pump can run in a VFD application

is dependant on several factors:
 Fluid velocities through the pump and the piping systems. For
normal wastewater you must maintain 2.5ft/sec in horizontal runs
and 3ft/sec in vertical runs to keep solids suspended.
 Meet the pump manufacturer’s minimum flow requirements for
the selected pump to avoid damaging recirculation cavitation.
This can range from 20% of BEP flow to 50% of BEP flow,
depending on the impeller design and operating speed.
 Maintaining high enough rotational speed to keep the motor’s
cooling system functioning. The min speed for proper cooling
system operation depends on the type of cooling system
provided.

Clogging issues with pumps on VFDs
Pumps running on VFDs are more prone to clogging than

constant speed pumps. This is because:
 At reduced speed, fluid velocities through the impeller and in the
piping can drop significantly allowing rag material to build up
 At reduced speed, material moves more slowly through the impeller
and volute and can build up, creating a clog.
 In the impeller, the natural scouring action which aids in rag handling
can be greatly reduced
 Material can build up in the discharge piping, and eventually back up
into the pump
 In dry pit, material can build up in the suction piping, and overwhelm
the pump with solids when the speed is ramped up

Other Important VFD setting and operational

parameters
Modern VFDs have many configuration options that must be

set during startup. Setting these parameters properly can
make the difference between a good VFD pumping
system, and a poor one.
 Constant torque/variable torque: Centrifugal pumps are variable
torque machines, so this parameter should always be set to
variable torque.
 Acceleration and deceleration ramp: Initial ramp setting should be
10 sec for both accel and decel. This should be tuned to field
conditions with the understanding that shorter ramp times are
usually preferable (especially with systems that have a high
percentage of static head). If water hammer is not an issue,
coast to stop is preferred over controlled deceleration.


parameters
 Slip compensation: This parameter should be turned OFF unless

the pump manufacturer specifically states that it should be on for
the particular application. Slip compensation attempts to run the
motor at full synchronous speed by increasing the max frequency
above 60 Hz. This can cause overload and overheating of the
motor.
 Minimum frequency: This must be set to an appropriate
frequency to meet the minimum flow requirements of the system
as previously discussed. Failure to set the minimum frequency to
an acceptable level can cause the level controls or an
unsuspecting operator to run the pump continuously at shutoff
head; damaging the pump.
 Maximum frequency: This should be set to the name plate
frequency of the motor (60Hz in N. America) to prevent over
speeding of the pump. Only set the max frequency above 60Hz if
recommended and approved by the pump manufacturer.

parameters
 Speed control settings: The control system should be set to ramp

up the pump to full speed and allow it to stabilize before dropping
it down to level control speed. This is normally accomplished
through the PLC or controller rather than through the VFD
settings. Systems that ramp up to control speed directly without a
short run at full speed are more likely to clog.
 Parallel pumps on VFDs: When multiple identical pumps are run
in parallel on VFDs, all pumps must be run at the same speed. If
a VFD pump is to be run in parallel with a constant speed pump,
the VFD pump must be run at full speed. Exceptions can be
made to the above rule if a detailed analysis of the pump curves
and system curve has been performed, and it is found that the
slower running pump will be running at an acceptable point on the
curve.

Summary
The general rules of thumb for selecting variable speed

pumping systems are:
 Applications where the static head exceeds 50% of the
duty head are not usually good applications for variable
speed pumping
 Select pumps so that the primary, full speed duty point is to
the right of the pump’s BEP (but watch NPSH margin)

Sulzer Pumps
Summary
Some other guidelines:

 Allow about a 5-10 percent motor power reserve at full speed to account
for extra heat generated in the motor
 Use motors that are acceptable for VFD service, and use appropriate
filters for long cable runs to prevent damage to the motor
 Size and select VFD and Motor combinations with an emphasis on
current, not horsepower, to be sure the VFD has adequate output
capability for the application.
 Carefully consider operational parameters for VFD stations to minimize
the possibility of clogging.
 Apply VFDs only where there is a real benefit in efficiency or process
control. Don’t fall for the argument that VFDs always improve the
efficiency and performance of pump systems, it’s simply not true. Some
systems can benefit, but many cannot.

Sulzer Pumps
The End
The Heart of Your Process

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Understanding Pump Curves Sulzer Pumps

Presenter: Michael Stroh – Application & Project Engineer, Sulzer Pumps

The Heart of Your Process

The Static Head is the total vertical

The Dynamic Head is determined by

The Dynamic Head of a system is

The Design Flow is determined by

Design The whole purpose of the System

The Pump Curve is then plotted on

The pump will always runs at this

Most pump stations actually have a

The full range of possible System

Low WW Level Static Head

High WW Level Static Head

When the Pump Curve is added to

The pump will operate at the higher

Low WW Level Static Head

High WW Level Static Head

Most commonly however a single

Customer presentation | May 2012 Copyright © Sulzer Pumps | Slide 9

Customer presentation | May 2012 Copyright © Sulzer Pumps | Slide 10

Customer presentation | May 2012 Copyright © Sulzer Pumps | Slide 11

 The static component is based on the vertical distance that the

Customer presentation | May 2012 Copyright © Sulzer Pumps | Slide 14

Customer presentation | May 2012 Copyright © Sulzer Pumps | Slide 15

Primary Benefits of Variable Speed Pumping

Secondary reasons to use a VFD can include:

Customer presentation | May 2012 Copyright © Sulzer Pumps | Slide 16

The Affinity Laws predict the Q1 n1

Since we don’t know the exact speed the submersible

Customer presentation | May 2012 Copyright © Sulzer Pumps | Slide 18

Calculating Using the Affinity Laws

Therefore, for a pump delivering 2000gpm at 100feet, with

Calculating Using the Affinity Laws

Reducing the frequency (and rotational speed) from 60Hz

Customer presentation | May 2012 Copyright © Sulzer Pumps | Slide 20

Example pump, 8” discharge, 4

Customer presentation | May 2012 Copyright © Sulzer Pumps | Slide 21

Reduced speed curves are

Flow reduction is directly

Reduced speed curves

Customer presentation | May 2012 Copyright © Sulzer Pumps | Slide 22

Lines of constant efficiency

Customer presentation | May 2012 Copyright © Sulzer Pumps | Slide 23

Example system curve

Full speed duty point is

Pump performance at any

Customer presentation | May 2012 Copyright © Sulzer Pumps | Slide 24

The same pump with a

Full speed duty point is

Customer presentation | May 2012 Copyright © Sulzer Pumps | Slide 25

First Rule of Thumb

First rule of thumb:

Customer presentation | May 2012 Copyright © Sulzer Pumps | Slide 26

10” pump selection with 25

Customer presentation | May 2012 Copyright © Sulzer Pumps | Slide 27

10” pump selection with 25

Efficiency increases as the

Efficiency falls to 65% at

Customer presentation | May 2012 Copyright © Sulzer Pumps | Slide 28

10” pump selection with 60

Customer presentation | May 2012 Copyright © Sulzer Pumps | Slide 29

10” pump selection with 60