Table Of ContentThis page intentionally left blank
Working Guide
to Pumps and
Pumping Stations
Calculations and Simulations
E. Shashi Menon, P.E.
and
Pramila S. Menon, MBA
AMSTERDAM BOSTON HEIDELBERG LONDON NEW YORK
OXFORD PARIS - SAN DIEGO SAN FRANCISCO SINGAPORE
SYDNEY TOKYO
Gulf Professional Publishing is an imprint of Elsevier
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Gulf Professional Publishing is an imprint of Elsevier
30 Corporate Drive, Suite 400, Burlington, MA 01803, USA
Linacre House, Jordan Hill, Oxford OX2 8DP, UK
0 2010 E. Shashi Menon. Published by Elsevier Inc. All rights reserved.
No part of this publication may be reproduced or transmitted in any form or by any means,
electronic or mechanical, including photocopying, recording, or any information storage
and retrieval system, without permission in writing from the publisher. Details on how to
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This book and the individual contributions contained in it are protected under copyright by
the Publisher (other than as may be noted herein).
Notices
Knowledge and best practice in this field are constantly changing. As new research and
experience broaden our understanding, changes in research methods, professional practices,
or medical treatment may become necessary.
Practitioners and researchers must always rely on their own experience and knowledge
in evaluating and using any information, methods, compounds, or experiments described
herein. In using such information or methods they should be mindful of their own safety and
the safety of others, including parties for whom they have a professional responsibility.
To the fullest extent of the law, neither the Publisher nor the authors, contributors, or
editors, assume any liability for any injury andor damage to persons or property as a matter
of products liability, negligence or otherwise, or from any use or operation of any methods,
products, instructions, or ideas contained in the material herein.
Library of Congress Cataloging-in-Publication Data
British Library Cataloguing-in-PublicationD ata
A catalogue record for this book is available from the British Library.
ISBN: 978- 1-8561 7-828-0
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Dedicated to our parents
Contents
Preface ix
Author Biography xi
Introduction 1
Pump Performance 23
Liquid Properties versus Pump Performance 47
Pressure Loss through Piping Systems 69
System Head Curves 113
Pump Performance at Different Impeller Sizes and Speeds 133
NPSH and Pump Cavitation 149
Pump Applications and Economics 157
Pump Simulation Using PUMPCALC Software 195
Appendices
A Summary of Formulas 207
B Units and Conversion Factors 22 1
C Properties of Water-USCS Units 227
D Properties of Common Liquids 23 1
E Properties of Circular Pipes-USCS Units 233
F Properties of Circular Pipes-SI Units 25 1
G Head Loss in Water Pipes-USCS Units 267
H Darcy Friction Factors 275
I Least Squares Method 277
References 281
Index 283
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This book is about the application of pumps and pumping stations used in pipelines
transporting liquids. It is designed to be a working guide for engineers and techni-
cians dealing with centrifugal pumps in the water, petroleum, oil, chemical, and
process industries. The reader will be introduced to the basic theory of pumps and
how pumps are applied to practical situations using examples of simulations, with-
out extensive mathematical analysis. In most cases, the theory is explained and fol-
lowed by solved example problems in both U.S. Customary System (English) and SI
(metric) units. Additional practice problems are provided in each chapter as further
exercise.
The book consists of nine chapters and nine appendices. The first chapter intro-
duces the reader to the various types of pumps used in the industry, the properties of
liquids, performance curves, and the Bernoulli’s equation. The next chapter discusses
the performance of centrifugal pumps in more detail, including variation with impel-
ler speed and diameter. The concept of specific speed is introduced and power calcu-
lations explained. Chapter 3 reviews the effect of liquid specific gravity and viscosity
on pump performance and how the Hydraulic Institute Method can be used to cor-
rect the pump performance for high viscosity liquids. The temperature rise of a liquid
when it is pumped and pump operation with the discharge valve closed are discussed.
Chapter 4 introduces the various methods of calculating pressure loss due to fric-
tion in piping systems. The Darcy equation, friction factor, the Moody diagram,
and the use of the two popular equations for pressure drop (Hazen-Williams and
Colebrook-White) are reviewed, and several examples illustrating the method of
calculation are solved. Minor losses in valves and fittings, and equivalent lengths
of pipes in series and parallel, are explained using example problems. Chapter 5
introduces pipe system head curves and their development, as well as how they are
used with the pump head curves to define the operating point for a specific pump
and pipeline combination. Chapter 6 explains Affinity Laws for centrifugal pumps
and how the pump performance is affected by variation in pump impeller diameter
or speed. The method of determining the impeller size or speed required to achieve
a specific operating point is explained using examples.
Chapter 7 introduces the concept of net positive suction head (NPSH) and its
importance in preventing cavitation in centrifugal pumps. Using examples, the
method of calculating the NPSH available in a piping system versus the NPSH
required for a specific pump is illustrated. Chapter 8 covers several applications and
