GE

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PROCESS ENGINEERING DESIGN GUIDE

PART 1 SECTION 1
PROCESS MANUAL (DATA BOOK)

Issued

Book N

Chapter N

312

1.1.2.

VIII

S.S. 1.2 : Process Equipment

CHAPTER VIII Pumps

CONTENTS

1.

PUMP SELECTION
1.1.
1.2.

2.

Pump selection
Flow control

CENTRIFUGAL PUMPS
2.1.

Incidence of main operating parameters

2.1.1. Modification of impeller's speed (n, rpm)
2.1.2. Modification of impeller's diameter
2.1.3. NPSH

2.2.

Main features of centrifugal pumps

2.2.1.
2.2.2.
2.2.3.
2.2.4.

2.3.
2.4.

Pumps operating in parallel

Rating point
Minimum flow
Materials of construction

Selection of centrifugal pumps

Power estimation
2.4.1.
2.4.2.
2.4.3.
2.4.4.
2.4.5.
2.4.6.
2.4.7.

Shaft power
Pump efficiency
Viscosity correction factor
Electrical motor efficiency
Criteria for motor selection
Power at reduced capacity
Pump suction specific speed Nss

3.

OTHER TYPES OF PUMPS

4.

IMPACT OF DISSOLVED GASES ON THE NPSH

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Chapter N

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S.S. 1.2 : Process Equipment

CHAPTER VIII Pumps

PUMP SELECTION
1.1.

Pump selection diagram

Refer to the selection chart enclosed overleaf.

The borderlines of the various areas are conservative. They may be exceeded after
Mechanical Department approval or based on Vendors data.
For reciprocating and rotary pumps, also refer to the tables given further in this
chapter.
As a general rule, centrifugal pumps should always be preferred whenever they can
be used, since they tend to be cheaper and more reliable.
They should generally not be considered in the following cases :
High viscosity (> 400 cSt)
High differential head at low flowrate.
1.2.

Flow control

Whatever the type of pump is, the flow can always be controlled by adjusting the
speed ; at a fixed speed, flow can be often adjusted through control valve, throttling
valve, etc.

GE 1 - ANG - rev. 0 - EG-312-1128.doc

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S.S. 1.2 : Process Equipment

CHAPTER VIII Pumps

PUMP SELECTION DIAGRAM

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S.S. 1.2 : Process Equipment

CHAPTER VIII Pumps

CENTRIFUGAL PUMPS
2.1.

Incidence of main operating parameters

2.1.1.

Modification of impellers speed (n, rpm)

For a given geometry :

The flowrate is directly proportional to n

The head H is directly proportional to n2
The power P is directly proportional to n3 (at fixed efficiency)
The efficiency is not affected significantly by a speed modification, excepted for
very low speeds where it slightly decreases.

2.1.2.

Modification of impeller's diameter

At a given speed
The Impeller shape offers a constant cross sectional area (exit velocity triangles

remain similar) :
- The flowrate is directly proportional to D
- The head H is directly proportional to D2
- The power P is directly proportional to D3 (at fixed efficiency).
The cross sectional area through the impeller increases with the diameter :

The flowrate is directly proportional to D2

The head H is directly proportional to D2
The power P is directly proportional to D4 (at fixed efficiency)
The efficiency slightly decreases when the impeller's diameter is reduced.

2.1.3.

NPSH

It is directly proportional to n2, but does not vary with the diameter of the impeller
(provided that the diameter reduction is less than 20%). The use of inducers allows to
decrease the NPSH required.
n : Impeller speed (revolution per minute, rpm).

GE 1 - ANG - rev. 0 - EG-312-1128.doc

Issued

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Chapter N

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1.1.2.

VIII

GE

GUIDE DOCUMENT

PROCESS ENGINEERING DESIGN GUIDE

PART 1 SECTION 1
PROCESS MANUAL (DATA BOOK)

Rev. Page

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S.S. 1.2 : Process Equipment

CHAPTER VIII Pumps

2.2.

Main features of centrifugal pumps

2.2.1.

Pumps operating in parallel

The performance curves should be drooping as much as possible to provide a good

operating stability. This can be achieved if the angle between impeller blades is less
than 18, which entails a slight reduction in pump efficiency.
2.2.2.

Rating point

The pump rating point shall be located as close as possible from the maximum
efficiency, but should not go beyond in terms of flowrate.
2.2.3.

Minimum flow

A minimum flow shall always be maintained in a centrifugal pump. This may require
a manual or automatic recirculation by-pass (restriction orifice, valve or "schroeder"
check valve).
The minimum flow is specified by the pump supplier. It is usually 20 to 30% of the
nominal flow, excepted for high-speed pumps, for which performance curves are
bell-shaped and the minimum flow can be up to 50% of normal flow.
2.2.4.

Materials of construction

Refer to the table enclosed overleaf.

2.3.

Selection of centrifugal pumps

The main characteristics of various types of centrifugal pumps are summarized in the
following table :

Centrifugal
pumps

Flowrate

Viscosity

(%)

NPSH
Required
(m)

Flow
control

(m3/h)

Single-stage pump
Single-stage pump

1500

10 to 80

1 to 4

Valve

Low

3000

10 to 80

1 to 5

Valve

Low

180

20000 max.

20 to 60

1 to 5

Valve

Moderate

< 500

35

3000

10 to 75

2 to 5

Valve

Moderate

< 500

140

3000

10 to 80

3 to 8

Valve

Moderate

Current
speed
(rpm.)

Efficiency

(cSt)

Differential
pressure
(bar)

2000

< 500

15

1500

< 500

35

Single-stage Sundyne
pump

90

< 500

Double-stage pump

250

Multi-stage pump

1500

GE 1 - ANG - rev. 0 - EG-312-1128.doc

Sensitivity
to solid impurities

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S.S. 1.2 : Process Equipment

CHAPTER VIII Pumps

MATERIAL SELECTION TABLE FOR CENTRIFUGAL PUMPS

G-2

GE 1 - ANG - rev. 0 - EG-312-1128.doc

API Standard 610

(8th Edition August 1995)

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S.S. 1.2 : Process Equipment

CHAPTER VIII Pumps

MATERIAL SELECTION TABLE FOR CENTRIFUGAL PUMPS

H-2

GE 1 - ANG - rev. 0 - EG-312-1128.doc

API Standard 610

(8th Edition August 1995)

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S.S. 1.2 : Process Equipment

CHAPTER VIII Pumps

MATERIAL SELECTION TABLE FOR CENTRIFUGAL PUMPS

H-3

GE 1 - ANG - rev. 0 - EG-312-1128.doc

API Standard 610

(8th Edition August 1995)

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2.4.

Power estimation

2.4.1.

Shaft power

P (kW ) =

2.4.2.

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1.1.2.

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S.S. 1.2 : Process Equipment

CHAPTER VIII Pumps

Q (m3 / h x P (bar)
36 x (pump ' s efficiency )

Pump efficiency

It can be estimated based on the chart enclosed further on.

2.4.3.

Viscosity correction factor

It can be estimated based on the chart enclosed further on.

The impact on pump efficiency can be significant above 5 cSt, especially in the case of
low flow and low pump head.
2.4.4.

Electrical motor efficiency

It can be estimated based on the table enclosed further on.

The motor efficiencies are given for a 75% load (from maximum power), which is usually
the case.
For motors exceeding 15 kW, the efficiency increases by 0.5% at full load and decreases
by 2% at half load.
2.4.5.

Criteria for motor selection

A standard nominal power shall be selected for the motor. The nominal power will be the
standard nominal power immediately above the absorbed power at design conditions.
API 610 selection criteria shall be followed, i.e. the ratio of motor nominal power and
pump shaft power at rating point shall not be less than :
1.25 if the shaft power at rating point is < 22 kW
1.15 if the shaft power at rating point is from 22 to 55 kW
1.1 if the shaft power at rating point is > 55 kW.

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S.S. 1.2 : Process Equipment

CHAPTER VIII Pumps

When the pump is specified for open-valve start-up, the absorbed power at maximum
flow (end of the curve flow / head) shall be considered to select the motor, excepted for
high specific velocity pumps for which the maximum absorbed power corresponds to
minimum flow.
Practically, to calculate the power at maximum flow (end of the curve flow / head), the
Mechanical Department will consider 125% of the flow at B.E.P. (Best Efficiency Point).
The standard nominal powers of electric motors are given alongside with motor
efficiency values in the table enclosed further on.
Generally, low voltage motors (380 V) are used so long as the nominal power does not
exceed 132 kW and high voltage motors (5500 V) for higher values. However, the limit
between low and high voltage tends to increase, and a limit of 160 or even 200 kW may
be considered. This is usually defined in a Project general specification.

Examples of calculations :

The shaft power required for a pump at design conditions is equal to 7 kW. From the
table given further on, we obtain :
Motor efficiency : 85% for a 7.5 kW motor
Motor efficiency : 86% for a 11 kW motor.

For the 7.5 kW motor, the absorbed power is 7 / 0.85 = 8.2 kW. This motor is not
acceptable because the absorbed power (8.2) exceeds the nominal power (7.5).
For the 11 kW motor, the absorbed power is 7 / 0.86 = 8.1 kW. This motor is acceptable
because the absorbed power (8.1) is lower than the nominal power (11).
Checking of the API 610 criteria
For the 11 kW motor, the ratio (motor nominal power / pump shaft power) equals 11 / 7
i.e. 1.57 > 1.25. The criteria is met.

GE 1 - ANG - rev. 0 - EG-312-1128.doc

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VIII

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S.S. 1.2 : Process Equipment

CHAPTER VIII Pumps

Example n 2
The shaft power required for a pump at design conditions is equal to 12.2 kW. From the
table given further on, we obtain :
Motor efficiency : 87 % for a 15 kW motor
Motor efficiency : 88 % for a 18.5 kW motor.

For the 15 kW motor, the absorbed power is 12.2 / 0.87 = 14 kW. This motor is
acceptable because the absorbed power (14) is lower than the nominal power (15).
For the 18.5 kW motor, the absorbed power is 12.2 / 0.88 = 13.9 kW. This motor is
acceptable because the absorbed power (13.9) is lower than the nominal power (18.5).
Checking of the API 610 criteria
For the 15 kW motor, the ratio (motor nominal power / pump shaft power) equals
5 / 12.2 = 1.22 < 1.25. The criteria is not met.
For the 18.5 kW motor, the ratio (motor nominal power / pump shaft power) equals
18.5 / 12.2 = 1.5 > 1.25. The criteria is met.
2.4.6.

Power at reduced capacity

The power at reduced capacity will be estimated by the following method :

w
w

Calculation of the power P at design flow Y

For a reduced flow x, the power P' will be :
x + Y
P' = P

2Y

2.4.7.

Pump suction specific speed nss

Nss = N x Q0.5 / (NPSH req3/ 4)

where :

N
Q
NPSHreq

: Rotating speed of the pump

: Flow by suction intake
: NPSH required for the pump

rpm.
m3/h
m

This criteria is used by the Mechanical Department for pump selection when a maximum
value is imposed by the Client ; If not, it is only used as a guideline.

GE 1 - ANG - rev. 0 - EG-312-1128.doc

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S.S. 1.2 : Process Equipment

CHAPTER VIII Pumps

The Nss is calculated for the flow giving the best efficiency with the impeller maximum
diameter. This means that for a same service, two pump suppliers will usually provide
different Nss depending on the position of the operating point.
In some particular cases, an increase of the NPSH required (consequently of the NPSH
available) can be desirable to get an acceptable Nss value. But this case is uncommon
because few suppliers can propose two NPSH for a same pump model (different wheels
for a same pump casing).
The Process Department does not have to verify this criteria ; It has to be done by the
Mechanical Department.

GE 1 - ANG - rev. 0 - EG-312-1128.doc

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GE

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CHAPTER VIII Pumps

Rev. Page

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S.S. 1.2 : Process Equipment

CHAPTER VIII Pumps

Extract of Standard of the Hydraulic Institute, New York, USA 1955

GE 1 - ANG - rev. 0 - EG-312-1128.doc

Rev. Page

1 15/22

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S.S. 1.2 : Process Equipment

CHAPTER VIII Pumps

EFFICIENCY OF ELECTRICAL MOTORS AT 75% LOAD

380 V

Nominal P
kW

5500 V

Efficiency
%

0.75
1.1
1.5
2.2
3
4
7.5
11
15
18.5
22
30
37
45
55
75
90
110
132

GE 1 - ANG - rev. 0 - EG-312-1128.doc

70
73
74
77
79
80
85
86
87
88
89
90
90.5
91
91.5
92
92.5
93
93.5

Nominal P
kW
160
200
290
400
500
750
1 000
1 500
2 000
3 500
5 000
> 5000

Efficiency
%
91
92
93
93.5
94
94.5
95
95.5
96
96.5
97
97

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S.S. 1.2 : Process Equipment

CHAPTER VIII Pumps

OTHER TYPES OF PUMPS

The main features of reciprocating and rotary pumps are summarized on the tables
enclosed further on.
Unless otherwise specified, the maximum flows indicated are limit values that may not be
compatible with the maximum differential heads. For border cases, the Mechanical
Department shall be consulted.
NPSH of reciprocating pumps
For reciprocating pumps, the pumped fluid is pulsed in the suction line. To produce this
acceleration, a certain amount of energy is required. This energy, which adds to the
frictional losses, is called "acceleration height". The NPSH available for a reciprocating
pump can subsequently be calculated by the following formula :

NPSHa = (HA HB) +

HA and HB
PA
TV
g
r
D PAB
HAB

GE 1 - ANG - rev. 0 - EG-312-1128.doc

( PA TV

(PAB )2 + (H AB )2
5
g x x 10

0.5

: Height in m
: Suction pressure in bar a
: Vapour pressure of the pumped liquid in bar a
: Gravity factor in m / s2
: Density in kg / m3
: Pressure drop due to friction in m
: Acceleration head

Equation 1 (Note 1)

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S.S. 1.2 : Process Equipment

CHAPTER VIII Pumps

For centrifugal pumps, HAB is nil and DPAB does not depend on the pump. The NPSHa is
independent of the selected pump.
For a reciprocating pump, HAB and DPAB depend on the pump, the NPSH available is
dependent on the selected pump :
D PAB : Pressure drop due to friction, is calculated for the maximum liquid velocity
HAB : Acceleration head, depends on the pumping rate.

During the preparation of the process specification, the characteristics of the pump are
unknown and the NPSHa (from equation 1) cannot be calculated. The NPSH given in the
process specification is the NPSHa for a non-pulsed flow, i.e. :
The NPSH available calculated is the one calculated as for a centrifugal pump, (HAB nil
and D PAB calculated for an average velocity which corresponds to the average flow
indicated in the specification).
Only after pump selection, provided that the piping layout at pump suction is defined, the
NPSH available for the selected pump can be given. Subsequently, the following note is
written on the process specification :
"The Mechanical Department must check with the supplier that the NPSH available
corresponding to the pump is compatible with its NPSH required."
D PAB calculation :
The pressure drop due to friction is calculated as for a centrifugal pump, but the
maximum liquid velocity, corresponding to the maximum instantaneous flow of the liquid
in the suction pipe, has to be considered. Depending on the type of pump selected, the
maximum instantaneous flow can be calculated by multiplying the average design flow
by the following factor :
Double-acting pump
Single-acting pump
Simplex
Duplex
Triplex
Quadruplex
Others

3
2
2
1.5
1.3

2
1.5
1.3
1.3
1.3

Note - If a pulsation dampener is installed on the suction line, the factor to consider is 1.2
whatever the type of pump is.

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S.S. 1.2 : Process Equipment

CHAPTER VIII Pumps

HAB Calculation :
H AB = 0.712 x K x

QxNxL
D2

Equation 2 (Note 2)

Where :
HAB
Q
N
D
L
K

:
:
:
:
:
:

In m
Average design flow in l/min
Number of rpm
Pipe diameter in mm
Pipe length in m
Factor depending on the type of the pump

Single-acting pump
Simplex
Duplex
Triplex
Quadruplex
Others

Double-acting pump

1.00
0.50
0.166
0.125
0.10

0.50
0.29
0.166
0.10
0.10

In case the suction line comprises several piping diameters, HAB must be calculated for
each section, and the results added.
The equation 2 above derives from the following assumptions :
The motion generated by the pump is assumed to be a harmonical one,
The fluid is assumed to be incompressible.

The first assumption is never realised. Usually, the motion generated by the connecting
rod-crank assembly exceeds the maximum values of the harmonic curve. This excess
depends on the ratio r = (length of the connecting rod / length of the stroke), which
commonly ranges from 1.5 to 2.
The maximum acceleration head must be increased by 25 to 35%.
The second assumption is checked when the suction pressure is close to the atmospheric
pressure, which is usually the case for reciprocating pumps.

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S.S. 1.2 : Process Equipment

CHAPTER VIII Pumps

Remark : When a pulsation dampener is installed on the suction line, the acceleration
head between the pulsation dampener and the pump must be calculated from equation 2.
The acceleration head between the drum and the pulsation dampener will be taken as 10%
of the calculated value from equation 2. The two heads have to be added to obtain the
total acceleration head.
Notes

4.

1.

There is a phase shift between the pressure drop due to friction D PAB and the
pressure drop caused by acceleration HAB (acceleration is maximum when the
velocity is minimum).
This phenomenon is taken into account by the term [(PAB)2 + (HAB)2]05 in
equation 1.

2.

Some sources indicate equation 2 as being unrealistic when the suction line is
very long.

IMPACT OF DISSOLVED GASES ON THE NPSH

The occurrence of dissolved gas in the liquids dramatically reduces the NPSH really
available at the pump suction.
It is then necessary to take some margins into account, deriving from past experience.
These margins shall be considered in the PDS and shall be clearly indicated to prevent
any misunderstanding with the Mechanical Department.
The following recommendations can be found in the literature :
BFW pumps :
Other pumps :

GE 1 - ANG - rev. 0 - EG-312-1128.doc

divide by 1.25
divide by 2 or consider liquid at bubble point.

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S.S. 1.2 : Process Equipment

CHAPTER VIII Pumps

MAIN FEATURES OF RECIPROCATING PUMPS

Type of
reciprocating pump

NPSH
Usual
Global
velocity efficiency required
%
m
rpm

Flow

Viscosity

m3/h

cSt

Direct acting steam

pump

100 (simplex)
250 (duplex)

1800

20 to 350 usually
700 and more possible

0-70

45-80

3-4

Speed adjustment by steam throttling.

Max. temperature: 400C

Controlled piston
pump (or plunger)

300 (multiplex)

1800

350 to 750 usually

2500 possible

20-450

55-85

4-5

Flow control : 0-100%

Max. temp. : about 500C

Diaphragm pump with

hydraulic control

20 by head

1000

350 usually
3000 possible (metal
diaphragm)

150-200

80

4-5

Max. temperature : 500C min.

Temperature : -70C
Very good tightness.
Flow control : 0-100% .
Typical use : loaded liquids.
High viscosities.

Diaphragm pump with

pneumatic control

50

1800

0-40

250000

500
3000
Possible

50-200

Dosing pump :
Maxi range
Usual range

0-10
0-3

Differential
pressure ( )
bar

2 to 4

20

4-5

(
) the maximum values indicated for flow and differential head may not be simultaneous.

GE 1 - ANG - rev. 0 - EG-312-1128.doc

Remarks

Max. temperature : 100C

Applicable to loaded liquids (up to
90%)
Extreme temperature :
- 5000C max.
- 2000C min.
Flow control : 0-100%
Flow accuracy : +/- 0.5%

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S.S. 1.2 : Process Equipment

CHAPTER VIII Pumps

MAIN FEATURES OF ROTARY PUMPS

Type of rotary
pump
Gear
Screw :
- 2 screws
- 3 screws
Vanes

Flow (1)

Viscosity

m3/h

cSt

Differential
pressure (1)
bar

Usual
velocity
rpm

Global
efficiency
%

NPSH
required
m

200

10 x 106

250

0-3000

50-90 (2)

3-4

1000-2000
1000

1 x 106
2 x 106

200
200

2000
up to 15000

50-90
50-90 (2)

3-4
3-4

400

1 x 106

25

0-1500

Remarks
Max. temperature : 3500C
Max. temperature : 3000C

Max. temperature : 2600C

Hydraulic pumps : 200 bar, 20 m3/h,
2000 rpm.

Pistons

up to 50

(3)

up to 700

2000-3000

Deformable rotor

20

20000

2-4

200-1800

10 to 30

Off centre Screw

200

1 to 200000

50

0-1500

50

1-5

Max. temp. : 80-900C

Can handle erosive particles.

Lobes

200

1 to 200000

5-20

< 700

30-40

1-5

Max. temperature : 1200C

Deformable stator

20

25000

5-15

0-200

30-50

Max. temperature : 950C

Can handle erosive particles.

Mouvex

120

3-5

250-1400

45-50

Max. temp. : 250-3000C

(1)
(2)

(3) These pumps are used in

hydraulic systems for which the
fluids have a 500/1000 cSt viscosity.
Max. temperature : 800C

The maximum values given may not be simultaneous.

These efficiencies commonly exceed 70% when the operating conditions (differential pressure + flow + viscosity) are in the
optimal range for the pump selected.

GE 1 - ANG - rev. 0 - EG-312-1128.doc