4 Water Services Pump Curves PDF

Performance Curves
© TEA. www.tea.ie 1
Performance Curve
Characteristics
Performance Curve
Characteristics
Operating Point
• The operating point of a centrifugal pump, also

called its duty point, is given by the intersection
of the pump characteristic curve with the
system curve.
• The flow rate Q and the developed head H are
both determined by the intersection.
• To change the operating point either the system
curve or the pump curve must be changed.
Pump Operating Point
Pump Range
Parallel Pumping
Multi-Stage Pump Range
Examples 2
Coolcorcoran Pumphouse
Coolcorcoran Pumphouse
POWER
PUMP COST PER
COMPANY PUMP OUTPUT ABSORBED MOTOR MOTOR PRICE
EFF. SPEED ANNUM
kW KW EFF.
800m3/hr @
A 87.0% 200.4 250 95.4% 1450 €52,777.50 €226,419.56
80m.
1
800m3/hr @
B 87.5% 199.3 250 95.4% 1450 €62,425.00 €225,125.73
80m.
800m3/hr @
2 C 87.5% 199.3 250 96.7% 1405 €55,301.74 €222,099.22
80m.
720m3/hr @
3 D 200 96.0% 1450 €55,759.15 €0.00
80m.
800m3/hr @
4 E 87.3% 199.8 250 96.4% 1535 €67,033.10 €223,300.81
80m.
Existing
680 @ 69 m 69% 185.3 93.0% 1450 €252,585.63
Pumps
Central Regional Water Supply
Coolcorcoran Station
Electricity Cost /
Consumption Chart
Lough Guitane
Pumphouse
Lough Guitane Pumphouse
POWER Pump
OUTPUT HEAD PUMP COST PER
PUMP ABSORBED N.P.S.H MOTOR MOTOR PRICE
M3/HR M. EFF. SPEED ANNUM
kW . KW EFF.
102150 €303,234.
A 1,080 53 86.0% 181.4 4.2m 250 95.0% 1450
+13620 40
1
82855+1362 €296,342.
B 1,100 53 88.0% 180.5 5.8 250 95.0% 1450
0 71
€296,626.
2 C 1,200 53 87.0% 199.2 4.6 250 96.0% 1329 €104,145.00
56
€298,179.
3 D 1,200 53 87.0% 199.2 3.9 250 95.5% 1350 €93,279.98
58
Existing €325,507.
1050 44 69% 185.3 93.0% 1450
Pumps 74
Kilsarcon Pump Station
Crohane Pumphouse
Crohane Pumphouse
POWER
PUMP PUMP COST PER
PUMP OUTPUT ABSORBED MOTOR PRICE
EFFICIENCY SPEED NPSH ANNUM
kW KW.
A 150m3/hr @ 108m. 77.0% 57.3 75 1450 2.1m €54,888.60 €30,129.85
1 B 150m3/hr @ 108m. 79.5% 55.5 75 1450 1.92m €72,430.03 €29,182.37
C 150m3/hr @ 108m. 78.6% 56.2 75 2900 3.66m €61,026.70 €29,516.52
D 150m3/hr @ 108m. 79.5% 55.5 75 1450 1.92m €69,689.00 €29,182.37

2
E 150m3/hr @ 108m. 78.6% 56.2 75 2900 3.66m €54,820.50 €29,516.52
3 F 150m3/hr @ 108m. 77.0% 57.3 75 1450 2.1m €63,348.89 €30,129.85
G 150m3/hr @ 108m. 79.5% 55.5 75 1450 1.92m €75,542.20 €29,182.37

4
H 150m3/hr @ 108m. 78.6% 56.2 75 2900 3.66m €66,587.05 €29,516.52
Mid Kerry W.S.
Crohane
Mid Kerry W.S.
Crohane
Ballybeggan Water Supply
Existing Pumping Plant New Pumping Plant

Flow rate 140 m3/hr 164 m3/hr
Head 107 m. 113 M.
Motor eff. 91% 93%
Pump eff. 56% 78%
Overall 51% 72%
System hydraulic power 41 kW 51 Kw
Power consumed from ESB 83 kW 74 Kw
ANNUAL ENERGY COST €25,023 €14,330
New Pumping Plant Cost €27,554

Payback Period 2.5 years
Ballybeggan
Monitoring and Targeting
Variable Speed
Motor Principles
• The speed of an induction motor is normally fixed

because the electricity supply frequency is fixed, as is
the number of poles in the motor.
• The speed ( ignoring slip ) is calculated from the
formula :
Speed(rpm) = 120 X frequency (HZ) / no of motor
poles
• i.e.: - a 2 pole motor on 50 Hz supply has a speed of
120 x 50 = 3000 rpm
• Equally a 2 pole motor on a 60 Hz supply has a speed
of 3600 r/min
• Therefore, by varying the frequency the speed can
also be varied.
Fan Affinity Laws
(Applies to all centrifugal loads)
100
Input Power (%)

80
60
40
20
0
0 10 20 30 40 50 60 70 80 90 100
Speed (%)
Flow proportional to the speed

Pressure proportional to the speed squared
Power proportional to the speed cubed
Pumping Water
Variable Speed Flow Control
• The performance of a pump is directly related to its

speed in rpm, providing there is no cavitation. The law
of similarity may be used.
• For example, doubling the Pump Speed
• Flow x 2
• Head x 4
• Power consumed x 8
Speed Change Formulas
VSD
Methods of control
There are two methods of control:
• Open Loop. The speed is simply controlled by a
potentiometer. The speed is set either by a person, or
perhaps by simple controls allowing perhaps 2-4
speeds, depending on the situation.
• Closed Loop. This is much more powerful, with the
user setting the flow, temperature, pressure, or
whatever else it is that they want to control. Using a
sensor, the VSD adjusts the speed automatically to
maintain this parameter. This will always give
optimum results, as long as it is set up properly!
Variable speed drive
control
• VSD allows you to vary the speed of a motor to match
precisely the demands of a system.
• Control a booster pump to operate in a variable flow
situation and still maintain a minimum pressure in a
distribution main.
• Allows you to use full size impellers in pumps to get
maximum efficiency.
• Unequal sized pumps can operate in parallel.
• Soft starting and stopping to minimize surges in water
mains.
• Precise control of oxygen level in a waste water
treatment plant.
Joint benefits of system
improvements
• Fitting a VSD not only saves energy,

but also:
– Reduced speed means less frictional
wear, longer bearing and seal life.
– It reduces water hammer and resulting
damage.
– Improved pressure control reduces
leakage
Motor Efficiency
Motor Efficiency
Reservoir
Real
work
Done Pump
losses
Motor
Pipe losses
losses
Motor (4)
Source
The European Efficiency
Labeling Scheme (2002-2010)
4 pole
2 pole
% Efficiency
kW
1.1 90
IEC 1-4
Motors and Legislation
Commission Regulation (EC) No 640/2009

(Directive 2005/32/EC)
In detail:
– IE2 by June 16, 2011
– IE3 by January 1, 2015 (for motors >=7.5 to
375 kW) and IE2 only in combination with an
adjustable speed drive
– IE3 for all motors by January 1, 2017, (for
motors from 0.75 to 375 kW) and IE2 only in
combination with an adjustable speed drive.
The Real Cost of
Rewinding a Motor
Repair Replace - HEM
Cost €1,233 €1,595
2 yr running cost €38,663 €37,622
Total cost €39,895 €39,217
Original - 90.5%
Repair - 90.0%
HEM - 92.5%
HEM saving - €679
Pipe Design
Suction/Inlet
Pipework Layout
Flow Velocities
• Suction pipes – 1 to 2 m/s
• Inlet pipes – 1.5 to 2.5 m/s
• Discharge pipes – 2 to 3 m/s
• The same velocities apply to

gate non-return and foot valves.
Pump Connections
• The right pipe size is a compromise between pipe cost and

excessive friction loss. Do the calculations and insure that the
pipe losses and velocities are at acceptable levels. Do not depend
on the size of the pump flanges, in most cases larger pipes and
valves are required. Use long radius bends and radial tees.
• A small pipe will initially cost less but the friction loss will be higher
and the pump energy cost will be greater. If you know the cost of
energy and the purchase and installation cost of the pipe you can
select the pipe diameter based on a comparison of the pipe cost
vs power consumption.
Control Systems
Flow Control by Throttling
• Changing the flow rate Q by operating a throttle valve

is the simplest flow control method not only for a
single adjustment of the flow rate but also for its
continuous control, since it requires the least
investment.
• But it is also the most energy wasting method, since
this method simply increases the head to reduce the
flow and thereby increases the energy consumed.
Reservoir Level Control
• Stop / Start
• PID
• Step Control
• Day / Night
Pressure Control
• Continuous Pumping.
• Control with 2 to 3 fixed speed pumps
• On /Off with Pressure Tank.
• Variable Speed Control – PID and Step
Control
Pump Protection
• Low Water Protection

• Loss of Prime - No-flow
• Burst Main
• High Pressure
• Bearing Over Heat
Motor Protection
• Over / Under current

• Overheat
• Voltage
• Power Factor
• Bearing Over Heat
Thank You!

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Performance Curves

• The operating point of a centrifugal pump, also

A 150m3/hr @ 108m. 77.0% 57.3 75 1450 2.1m €54,888.60 €30,129.85

1 B 150m3/hr @ 108m. 79.5% 55.5 75 1450 1.92m €72,430.03 €29,182.37

C 150m3/hr @ 108m. 78.6% 56.2 75 2900 3.66m €61,026.70 €29,516.52

D 150m3/hr @ 108m. 79.5% 55.5 75 1450 1.92m €69,689.00 €29,182.37

3 F 150m3/hr @ 108m. 77.0% 57.3 75 1450 2.1m €63,348.89 €30,129.85

G 150m3/hr @ 108m. 79.5% 55.5 75 1450 1.92m €75,542.20 €29,182.37

Existing Pumping Plant New Pumping Plant

ANNUAL ENERGY COST €25,023 €14,330

New Pumping Plant Cost €27,554

• The speed of an induction motor is normally fixed

Input Power (%)

Flow proportional to the speed

• The performance of a pump is directly related to its

• Fitting a VSD not only saves energy,

Commission Regulation (EC) No 640/2009

Cost €1,233 €1,595

2 yr running cost €38,663 €37,622

Total cost €39,895 €39,217

• Suction pipes – 1 to 2 m/s

• Inlet pipes – 1.5 to 2.5 m/s

• Discharge pipes – 2 to 3 m/s

• The same velocities apply to

• The right pipe size is a compromise between pipe cost and

• Changing the flow rate Q by operating a throttle valve

• Low Water Protection

• Over / Under current

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