I CI-O 1-6-2

Why Did I Buy Such an Oversized Pump?

Roy C. E. Ahlgren
Associate Member ASHRAE

ABSTRACT impeller’s best efficiency point (BEP) for a constant speed

pump. Typical recommended intervals around the BEP are
Centrifugalpump oversizing results in higher initial cost,
shown in Figure I . A more detailed version can be found in
higher operating costs, and increased maintenanceproblems
ASHRAE (2000a). All else being equal, this will minimize the
over the life of the system when compared to a properly sized
energy costs of operating the pump. For typical HVAC load
pump. It is easy to preach that pumps must not be oversized,
profiles, selection close to BEP will result in obtaining a pump
in spite of publications and guidance that goes well back in
that will operate most of the time in the middle of its curve at
time, pumps are still being specified for much greater head
higher efficiencies. The expected range of flow rate variation
than actually required by the system. Experience in working
should be considered in order to determine if the pump would
with a large number of designers has uncovered manyfactors
be operating at very low or very high flow rates far away from
that lead to pump oversizing. Some of these are pure misun-
the BEP. Constant flow components or controls may be added
derstanding orfailure to adequately analyze the systempump-
to the system to help avoid long periods of operation at low
ing requirements. Thesefactors can be addressed by training,
flow rates.
making sure designers know the elements of pump selection
and sizing. Other factors are not so easy to reme&, leaving A pump that operates toward either the far right or left of
even experienced, knowledgeable designers with the real the curve will usually be operating at a lower efficiency. It will
possibility that the pumps they specify will be oversized. This also experience unbalanced forces on the impeller that can
paper will detail the reasons thatpumpsget oversizedandoffer impose large radial loads on the bearings. This will result in
some suggestions about how to solve the problem.
BEPIFlow
INTRODUCTION
Pumps are selected from printed curves or, more
commonly today, from computer-based selection programs. ti ead
(ft)
Whatever the means, the specifier must determine the desired
head and flow. After that, it is simply a matter of choosing a
pump design suitable for the installation and selecting a model
and impeller size that have the best combination of efficiency
and flexibility. The pump performance curves are plotted on
headlflow coordinates, based on actual tests of the pump 1.15
PeicettBEPflow
model, using test procedures specified by the Hydraulic Insti-
tute.
The intersection of required head and flow on the pump Figure 1 Typical recommended intervals around the
curve should occur close to, or perhaps a little to the left of, the impeller S best eficiency point (BEP).

Roy Ahlgren is the director of training and education at ITT Bell & Gossett, Morton Grove, Ill.

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 premature wear and failure of the bearings and seals. The
intersection of required head and flow should occur neither on
the maximum nor the minimum impeller diameter for a given
volute. By avoiding the extremes, the specifier can build in a
little “wiggle room” to adjust pump performance after it is
installed in the system and actual flow and head measurements
can be made. Based on these actual performance data, the
impeller can be trimmed to a smaller diameter or replaced with
a larger diameter impeller if need be.
Unders¡zed Pumps
Pump oversizing is still more common than undersizing,
but undersizing is becoming an issue too. Sometimes a prop-
erly sized pump gets downsized in order to reduce the first cost
of the project. This undersized pump will operate far to the
right of its best efficiency flow and be susceptible to high bear-
ing loads and perhaps even cavitation damage that will
increase the cost of ownership over the life of the system.
Cavitation can result because the pump operates at the extreme
flow rates allowed, with consequently high values of NPSHR
(Net Positive Suction Head Required).
Oversized Pumps
By “oversizing” let’s assume we mean the specifier has
selected a pump that is capable of providing a lot more head
at required system flow than the system will ever need. The
consequences, in terms of the effects on the pump, are similar
to the undersized situation in many respects, but there is the
additional factor of higher initial and higher operating costs. In
an extreme case of oversizing, even the minimum diameter
impeller is too large. It can be very expensive to remove and
replace this oversized pump, but it can also be very costly to
operate it at low efficiency, at excess flow, or with excess
throttling at the pump discharge. Less severe oversizing can be
remedied by replacing the large impeller with a smaller one.
DETERMINING DESIGN FLOW REQUIRED
Flow requirement is relatively easy to determine in
hydronic systems. The whole point in these systems is to trans-
fer heat using water, or perhaps another liquid, as the heat
transfer medium between the high temperature of the boiler
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and the more moderate temperature of the terminal unit. In the
case of a chilled water system, heat transfer is from the higher
temperature of the terminal unit to the lower temperature of
the chiller evaporator or some other low-temperature heat
sink. A load calculation program can be used to calculate the
required rate of heat transfer. Then the designer selects a
design temperature difference (At). In a heating system, the At
is the temperature drop across the terminals (rise across the
boiler). In a cooling system, it is the temperature rise across the
system (drop through the chiller). The flow required is then
calculated by:
Flow =
H e a t Load
C x At
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The constant (C) depends upon the units ofmeasurement,
the specific gravity, and the specific heat of the liquid. In many
flow formulas using conventional units and water, the value is
500. At temperatures higher than standard, or if other chemi-
cals are added to the water, that constant must be adjusted (see
ASHRAE 2000b for additional details).
Load calculations tend to be on the conservative side,
overstating, at least a little, the rate of heat transfer for a given
structure. Those who carry out these calculations will proba-
bly err on the side of anticipating more, rather than less, heat
load. Thus, there is likely to be at least a small overestimation
of flow requirements from the very beginning of the design
process. This is a minor factor in explaining why pumps are
oversized.
In other applications, the flow would be determined
differently. For example,
a cooling tower manufacturer might require that the
condenser pump provide three gallons per minute per
ton (O. 19 L/s per 35 17 W);
in sewage pumps, a local code may require some mini-
mum flow per bathroom;
a process flow requirement may be specified without
any further explanation.
The point is that most of the time flow requirements are
pretty well defined, at least initially.
A problem may arise when there is reason to expect a
change in flow demand sometime in the future. The specifier
must then decide how to handle the change, if and when it
occurs. The choices include
installing a pump now that is large enough to handle the
increased demand later or
installing two parallel pumps now, but only using one
(the second pump can be staged on when the increased
flow demand occurs).
In the first choice, the pump is oversized until the
increased demand occurs. This alternative has the disadvan-
tages of
high initial cost, providing pump capacity that might
never be actually required, and
high operating costs of throttling until the expected flow
demand actually occurs.
In the second case, careful design of the piping for the
expected flow increase, and providing a large enough motor
for single pump operation in the interim, will provide a good
compromise design.
DETERMINING DESIGN PUMP HEAD REQUIRED
There is often misunderstanding of the term “pump head”
because it is measured in feet (meters), apparently the same
unit used to measure system height. Later we’ll discuss how
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 that misunderstanding sometimes contributes to oversizing
pumps. But for now, let’s define pump head in terms of the job
that the pump is required to d o - move a liquid from one place
to another in spite of its weight and the friction that always
exists in a real system. It takes work to move anything that has
weight. The amount of work is determined by the force
required to accelerate the weight against the frictional resis-
tance that tends to keep it in place and the distance the weight
is to be moved. If a pump is doing Xamount of work on each
pound (kg) of water, we can more correctly think of pump
head as specific work, or work per unit weight.
Bernoulli’s statement of total fluid head is a convenient
way to discuss pump head requirements.
where
P, pressure, in lb/@, (Pa) at either location a or b
= same point at the same time. In this special case, pump head
W = density of the liquid in lb/ft3 (kg/m3)
Z, = elevation of the liquid at either location in ft (m)
compared to a reference level
V, = velocity of the liquid at either point, in Ws (m/s)
g = standard gravitational constant in ft/s2(m/s2)
Ep = pumpheadinft(m)
Hf = fixtion head loss in ft (m)
This relationship is completely general, covering the
amount of head required from the pump in any system. It
describes the total fluid head at Point A as the sum of the
pressure head at A,
elevation head at A,
velocity head at A.
In order to move the water from A to B, The pump must
provide Ep ft (m) of head, resulting in a new condition at point
B, with new values for pressure, elevation, and velocity head.
Hfcovers the total friction head loss from A to B. Solving for
the pump head required gives:
So pump head is the sum of pressure difference, elevation
difference, velocity head difference, and friction head loss for
the system.
In any specific system, one or more of these terms could
be zero.For example, if the source and the destination of the
liquid are at the same pressure, there is no difference between
them, and the pressure head term goes to zero. Similarly,
elevations and velocities could be the same at both points,
requiring no pump head to change them.
The velocity head term is often small enough compared to
the other terms that it can be ignored without significant error
in typical HVAC systems. Of course, it is not difficult to imag-
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ine a fountain or spray pond where velocity head would repre-
sent a major factor in determining pump head, but those are
rare applications in HVAC. For this reason, the velocity head
difference is often ignored, leaving pressure differences,
elevation differences, and friction head loss as the primary
components of pump head.
Closed Systems
A special case is the closed, or circulating system.
Systems such as these are very common in HVAC design
work; chilled water systems and hot water heating systems are
examples. Since they are circulating the same liquid through
the same piping system, points A and B in Bernoulli’s equa-
tion could be arbitrarily chosen to be the same point. Looking
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at it this way, we see that the pressure head, elevation head,
and velocity head terms must be zero, since it’s impossible to
have two different pressures, velocities, or elevations at the
required is determined only by the system friction head loss.
FRICTION HEAD LOSS
Several experimenters have developed expressions for
calculating friction head loss.
ASHRAE (1 997) includes the Darcy-Weisbach equation
for fully developed flow:
Hf -- dL)(q
D 2g
The friction head loss, Hr, represents the loss due to “fric-
tional shear at the bounding walls.” This energy is converted
to heat which, is “generally unrecoverable (a loss).” The units
for this term are the same as discussed above, in this case,
specific work expended in overcoming friction. This repre-
sents yet another reason to avoid oversizing pumps, especially
those in chilled water systems. A recently published rule of
thumb states that “each hp of chilled water pump power ...
must be offset with 1/5 ton of refrigeration” (Avery 2000).
This is true only if the water horsepower, not the brake horse-
power, is considered since motor inefficiencies do not gener-
ally serve to increase chilled water temperatures. Further,
there may be some small losses in the pump that do not raise
water temperatures (e.g., external bearing friction). But the
point is certainly true that pump input power has an effect on
chiller load.
In the Darcy-Weisbach equation,fis the friction factor, a
dimensionless number that is displayed as the ordinate of the
well-known Moody diagram shown as Figure 13 on page 2.9
of ASHRAE (1 997). The factors that determine friction factor
include the Reynolds number and the relative roughness of the
pipe. The Reynolds number is a function of the fluid viscosity,
fluid velocity, and diameter of the pipe. The relative roughness
is a dimensionless measure of the peaks and valleys on the
inside of a pipe or section of tubing.
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- 1

Figure 2 System with multiple circuits.
L is the length of the pipe. D is the pipe diameter (both
L and D are measured in the same units). V is the velocity
in Ws ( d s ) . G is the gravitational constant in Ws2( m / s 2 ) .
Analog slide rules are available to quickly determine the
friction loss rate for a given water flow through a given pipe.
They can also compute the total head loss through an equiva-
lent system length for a given friction loss rate. Recently, a
computer-based version of the slide rule has been published
that is not limited to water but can be programmed for a wide
variety of fluids of different viscosities. The range of pipe
sizes has been greatly increased too. These are available free-
of-charge on the Internet.
The concept of “equivalent length” is used to account for
the friction head loss through fittings.Recent ASHRAE-spon-
sored research is leading to a much better understanding of the
actual fitting head loss. The details will be published in the
ASHRAE Handbook as they become available.
REASONS FOR PUMP OVERHEADING
Pumps are sometimes selected without any clear analysis
at all. This usually results in greatly overheaded pumps that
must then operate with severe throttling at the pump discharge
in order to prevent excess flow. An analysis like this will illus-
trate the point. “Our current project is pretty similar to the one
we did last year. We used a 100 horsepower pump in that
project, and I haven’t heard any complaints, so I guess a 100
horsepower pump will be OK for this one too.” An absence of
“complaints” is certainly not evidence of a good pump selec-
tion. Flow noise or pipe erosion is cause for complaint, but
excess flow may not be great enough to cause these obvious
problems. The oversized pump costs more initially and costs
more to operate than a properly selected pump. Aside from this
obvious answer to “Why did I buy such an oversized pump?”
here are some other answers.
Some Errors in Determining Pump Head
Involve the System Static Pressure
Pump head is sometimes incorrectly estimated by inciud-
ing the system static pressure as a component of the required
pump head. Knowing that the system is designed to operate
under some positive pressure in order to vent gasses or keep
the water from boiling, some specifiers have converted that
pressure to an equivalent value in ft of head, then added it to
the total pump head requirement. The thinking goes that this
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internal pressure is pushing back against the pump, so it must
be included in determining the required pump head.
A better way of looking at it would be to realize that the
system pressure is pushing back equally on both the pump
suction and discharge, so the net effect of system pressure is
zero, so far as pump head required is concerned.
BUILDING HEIGHT
Some pump specifiers who have confused the system
height with the pump head requirement make a related
mistake. The thinking goes something like this: “I need to
pump water through a system that’s 100 feet high, therefore,
I must need 100 feet of pump head.” Since the system height
and the pump head appear to be measured in the same units,
it’s an easy mistake to make. But as we have seen, the pump
head in a closed system is determined only by the friction head
loss and the actual units are specific work, not length. On the
other hand, to say that system height is absolutely not related
to required pump head is incorrect because the taller the
system, the longer the pipe runs, and the longer the pipe runs,
the greater the friction head loss. In a closed system though, it
is irrelevant whether the closed piping loop is vertical or hori-
zontal. Pump head in a closed system is determined by the fric-
tion head loss regardless of loop orientation.So does that mean
that the system height is absolutely irrelevant in the selection
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process? No! The taller system will exert a greater static pres-
sure against all of the components at the bottom, including the
pump. All the flanges, gaskets, seals, and other materials must
be capable of withstanding the combination of static pressure
produced by the height of the system plus the pump head pres-
sure at that point.
An interestingrelated example occurred where a designer
had properly calculated the pump head required for a closed
system in a tall building but found that the flow was well below
design value at start-up. The first reaction was “we need more
pump head!” The problem was corrected when he checked the
system fill pressure. Although the static head was substantial,
it was less than was actually required to fill the system to the
top. In reality, the pump was in an “open system,” and had to
lift water through the total static head measured from the “at
rest” level to the top of the system. Once the system was prop-
erly filled, the pump head was adequate to overcome friction
head loss at design flow.
It has been said the compression tank will get the water
out to the end of the system. The implication is that the pump
head has no role in getting the water out to the end of the
system. In a very limited sense, that is true, but only when the
empty system is being filled. In order to cause flow, there must
be a difference in pressure, and that is provided by the pump.
OTHER CAUSES OF POOR PUMP SELECTION
INVOLVE MISTAKES IN ANALYZING THE SYSTEM
Identification of the “Worst Case” Circuit
In a system that has multiple circuits, such as the one
shown in Figure 2, designers correctly calculate the pump
flow requirement by adding up all the individual flow require-
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Total
Static
static Head
Dischaige
Head I Aging Allowance in Friction Head Loss Calculations
Static Suction
Head
Figure 3 Total static head.
ments. Then they add the friction head losses in all circuits to
obtain a greatly overstated value for pump head. The subcir-
cuit that has the highest head loss at design flow is the one that
establishes the pump head requirement. If the pump can
develop enough differential head to handle this worst-case
circuit, it clearly has more than enough to handle the lower
head loss circuits. Of course, there can be only one value of
differential pressure at one time between any two points such
as A and B. In the direct return circuit, the higher-than-needed
differential in the nearer circuits will force a greater-than-
required flow through those circuits. Careful selection of the
piping, terminals, control valves, and balance valves in these
nearby circuits can prevent excess flow. Since the most distant
circuit determined the pump head required, and since there is
no need for a balance valve in that circuit, the balancing valves
had no impact on the determination of pump head. If, by
mistake, a balance valve is adding extra head loss in the high-
est head loss circuit, then the required pump head will be larger
than actually required.
Incorrect Allowance for Elevation Differences
A specifier selecting a condenser water pump used the
static discharge head of the system to calculate the required
pump head rather than the total static head. As a result, the
pump was considerably oversized, causing excess flow. The
elevation term in the Bernoulli equation is interpreted as the
difference between the water levels, or the total static head
(Figure 3).
Failure to Allow for Adequate Pressure
Drop Across the Control Valves
Often, the person who specifies the pump does not specify
the control valves. The modulating control valve must be
selected with an adequate pressure drop at design Bow to mini-
mize the distortion of its inherent characteristic. ASHRAE
(2000b) covers this subject in detail. Unless there is some
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coordination between the two activities, pump head being
provided may be in error. The valve specifier must be espe-
cially careful to ensure that the pump shutoff head is consid-
ered when the valve actuators are chosen to ensure that they
will be able to close against the action of the pump. If the
valves cannot close, flow control at low load is lost. Analysis
of the system to avoid pump oversizing is clearly an important
issue in this respect.
Analysis of the friction head loss is especially important
in closed systems since it is the only component in determin-
ing the pump head requirement. Sometimes an artificial aging
factor is included to account for a decrease in pipe diameter as
the system ages and deposits build up on the inside of the
pipes. Some older references on piping head loss suggest
using a 15% safety factor for piping in commercial installa-
tions, then go on to state “No allowance for aging of pipe is
included.” The aging factor serves to increase friction loss by
some significant percentage; many designers simply apply an
extra 15%. In a closed system using mechanical seal pumps
and having a correctly sized compression tank, there will be
very little loss of water in normal operation and consequently
very little need for makeup water. Under these conditions, the
oxygen in the system will quickly be depleted as it combines
with the metal to form rust. The rest of the system then
becomes chemically inert and no appreciable scale or deposits
will be formed. The pump that was overheaded to account for
this buildup will require severe throttling to avoid excess flow.
In an open system that is continually exposed to new
sources of oxygen or other chemicals that could cause a
buildup of deposits, pipe aging should be taken into account.
This topic is in the long-range research plan for ASHRAE
Technical Committee 6.1, Hydronic and Steam Systems and
Equipment.
Safety Factors
There is a lot of pressure on contractors to make changes
in the original design. Many events can cause an increase in
the friction head loss of the system:
Initial costs can be reduced by substituting the next size
smaller pipe or component.
The contractor has smaller pipe on hand and none of the
larger size specified in the design.
Last minute changes require re-routing the piping and
increasing its length.
A higher head loss terminal is substituted for the origi-
na1 equipment, which is not available.
I
A careful designer who has faced these kinds of problems
in the past may add a significant safety factor to the pump head
requirement to cover these possibilities. This is often a signif-
icant factor in oversizing.
Manufacturer’s Lead Times
Given long lead times, and sometimes uncertain delivery,
the pump must be ordered well in advance of the actual instal-
ASHRAE Transactions: Symposia
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 lation date. The specifier may be forced to make decisions
about pump head before all the data are available. A conser-
vative approach would be to speci@ “more than enough”
pump head. Of course, the safety factor mentioned above will
then be applied to this ballpark value.
“There’s Not Enough Time to do the Analysis”
Some designers complain that the time and money avail-
able do not allow for the detailed analysis that would avoid
pump oversizing. If that is true, then just what does it mean to
“design” a system? If the analysis cannot be done, then just
how are the system components being selected? Is it really a
system, or just a collection of components?
There is no question that time and money are always tight,
but it is also true that the engineering analysis required to do
the job right is fundamental to the process. The answer lies in
using the resources that are already available to get the job
done in the time available and within the budget established.
For example, many universities and manufacturers offer very
practical, short training courses that can provide the designer
with the understanding required to get the design done right
without the need for time-consuming revisions and correc-
tions. A few days spent in learning how to design and analyze
the system is time well spent.
Computer-based design aids speed the piping layout and
pipe-sizing decisions.
Modern equipment selection programs slash the time that
used to be spent poring through catalogs.
“Variable Speed Eliminates the
Need for this Analysis”
Many designers have incorporated variable speed drives
for the hydronic pumps in their systems with the goal of reduc-
ing operating costs during periods of part load. The success of
these variable speed systems in saving money has been
impressive. The power electronics industry promises contin-
ued improvement of the variable speed drives in terms of
reduced cost, size, and cooling requirements, making variable
speed a real option for smaller and smaller pumps.
One unfortunate result of this success has been an attitude
that the specifier no longer has to analyze the pump head
required by the system, since the drive will act like an auto-
matic impeller trimmer.
In a very real sense, this is true, because a properly
controlled drive system will slow down an oversized impeller
to provide only the head and flow required by the system at the
time. A careful analysis is still required since the higher initial
cost of the drive system is justified by the reduction in energy
costs expected to result from its use at part load. These savings
are not automatic. A careful analysis is required in order to
achieve them. An oversized pump could require a larger motor
and drive compared to a properly sized pump. In order to real-
ize maximum energy savings, the pump impeller must still be
selected by analyzing the system. To see why this is true,
imagine an oversized impeller capable of delivering much
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greater head and flow than the system actually needs. The
pumping system sensors and controller will limit the rpm of
the impeller even at full load, making it perform like a trimmed
impeller, but drive efficiency falls off slightly as rpm drops,
and the drive will never be at full rpm with the oversized
impeller. At part load, the pump will be slowed even further,
but there is a minimum speed below which the system differ-
ential pressure sensors will not be satisfied. For a given
system, the oversized impeller could be operating at lower
efficiency compared to the right-sized impeller. As a result,
the expected energy savings may not be realized. The solution,
of course, is to avoid grossly oversizingthe pump, and the only
way to do that is to carry out the analysis in order to determine
the highest head loss circuit because it determines the pump
head required. The properly sized impeller will need close to
full speed at full load. At part load, the drive slows down the
impeller as before, but, properly selected, it can operate at a
higher efficiency more of the time. If the system has a signif-
icant constant head component, it is often useful to select the
variable speed pump a little to the right of the BEP in order to
maintain higher pump efficiency over a wider range of speed
variation.
In the case of variable speed pumps, there is another very
important reason to do the analysis. Location of the sensor that
supplies the controllerwith the differential pressure at the load
is an important element in permitting the variable speed
system to save the greatest amount of energy. It is often
pointed out that this sensor must be located as far away from
the pump as possible. In this context, “far away” really means
“at the terminai that is in the greatest head loss circuit.” How
will the designer know which circuit has the highest head loss
if the analysis has not been carried out? That same analysis is
fundamental to achieving flow balance, since the balancing
valve in that circuit is the one that must be left wide open.
RECOMMENDATIONS TO AVOID THE PROBLEMS
Pump sizing is an integral part of the design process. In
order to avoid the problems caused by improperly sized
pumps, a designer must
understand how pump head must be calculated in order
to provide adequate flow for heat transfer,
analyze the system using the tools available to find the
correct value,
avoid excessive safety factors, and
provide a way to adjust the pump performance after
actual head and flow measurements can be taken in
place.
REFERENCES:
ASHRAE. 2000. 2000 ASHRAE handbook-Systems and
equipment, chapter 39, Figure 3 1. Atlanta: American
Society of Heating, Refrigerating and Air-conditioning
Engineers, Inc.
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 ASHRAE. 2000. 2000 ASHRAE handbook-Systems and
equipment, chapter 12. Atlanta: American Society of
Heating, Refrigerating and Air-conditioning Engineers,
Inc.
ASHRAE. 1997. 1997 ASHRAE handbook-Fundamentals.
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Copyright American Society of Heating, Refrigerating and Air-Conditioning Engine
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No reproduction or networking permitted without license from IHS
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ASHRAE Transactions: Symposia
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