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Pumping Prescriptions

Dr. Lev Nelik, P.E., APICS

The Basics About


Pump(s)-to-System(s)

I
n most training exercises or general discussions of pump-
system interactions, great simplifications are made. The
two most common examples presented are usually two
pumps operating in parallel, or two pumps operating in
series. Discussion rarely involves more than two pumps, and
operation of a single pump against a multi-branched system
is discussed even less frequently.
But real installations rarely resemble such isolated and
greatly simplified situations. Typically in actual practice, mul-
tiple pumps operate against multiple branches of a system, or
several interconnected complex systems operate with pumps
coming on- and offline and valves adding multiple new
P1 P2
branches or shutting off parts of the system.
Such multi-branched, multi-pump systems can no
longer be analyzed by hand with a graph and calculator.
Instead, an entire computerized network of the plant piping,
tanks, and pumps that reflects proper sizes, friction, eleva-
tions, and so on needs to be carefully modeled.
However, before attempting to model the complexities
of the entire plant, the fundamentals of the multi-pump,
multi-branch systems that are in place must first be under- Case (a). (2) pumps in parallel against (1) system.
stood. When such an examination is reviewed, it will become
clear that the entire complex network is essentially a combi-
nation of the following three cases:
a) Several pumps in parallel, against a single system
b) Several pumps in series, against a single system
c) A single pump against a two-branched system, or against
a multi-branched system

To the right is a simplified example exercise involving


three cases that were excerpted from one of our training
P2
classes. Consider the fundamentals of three such cases as basic
building blocks for an eventually more complex network:
Cases (a) and (b) are more common, i.e. a single-
branched system is considered. Case (c) is less frequently
considered, but it has one pump against a multiple-branched P1
(two in this illustration) system. Graphically, in parallel oper-
ation, (pump curves) flow is additive at constant head; in
series operation, the (pump curves) head is additive at con-
stant flow.
However, for a multiple-branched system the flow is
additive (system curves) at constant head. Graphs (a), (b),
and (c) below reflect the three cases above, respectively. The
operating point is an intersection between the final pump
curve and a final system curve, as shown with numerical Case (b). (2) pumps in series against (1) system.
examples below.

24 APRIL 2007 www.pump-zone.com Pumps & Systems


h1

h2
Q1 h Q2
Q1 + Q2

P
Case (c). (1) pump against (2) system branches.

Computerizing the Process (2) H = h2 + k2 x Q22 This is the general equation for a
This process can be computerized, as illustrated in a sim- system of branch (2), including static head h2 and friction with
plified example of a positive displacement pump operating system friction resistance k2.
against two systems (two branches). Underlying programming
formulas are: (3) Q = Q1 + Q2 This is what leaves the pumps splits
into branches.
(1) H = h1 + k1 x Q12 This is the general equation for a
system of branch (1), including static head h1 and friction with Known/given: Q, k1, k2, h1, h2 (where h1 and h2 are static heads
system friction resistance k1. for the two systems, and k1 and k2 are friction coefficients for
these systems)

H H
m
m

ste
ste

Sy
Sy

400

400 200 200 200


X

200 (2)
200 250 250 250
X
X

(1) (2) (3) (1)


Q
Q
Graph (a). (2) pumps in parallel against (1) system. Method of con-
struction of multiple (combined) pump curve: at constant head line Graph (b). (2 or more) pumps (or pump stages) in series against
(200-ft), double the flow (250-gpm x 2) for a point on a 2-pump (1) system. Method of construction of multiple (combined) pump
curve. Repeat at several other constant head lines; for 400-ft, curve: at series of constant flows, add pump (or pump stages
double the flow (200-gpm x 2). For 3-pump operation, triple the for multiple pumps) heads. Intersections between the resulting
flow at constant head lines. Continue in the same fashion for more pump curve (stages curve) and a system curve establishes oper-
pumps. Intersections between one, two, three, or more pumps, ating point (resultant head and flow).
with a given system curve, establish the operating point (resultant
head and flow) for multiple pumps.

Pumps & Systems www.pump-zone.com APRIL 2007 25


Pumping Prescriptions

Need to find: Q1, Q2 and pump head h. e. If calculated flow is different than given, re-guess h and
repeat the process until error is small
Programming procedure:
a. Guess h Only when these fundamentals of the pump(s)-to-system(s)
b. Calculate Q1 from (1) principles are understood are you ready to take the next step a
c. Calculate Q2 from (2) computerized analysis of complex pumping systems.
d. Calculate Q = Q1 + Q2 and compare with given Q A parting quiz: how would a procedure change if two
pumps had an entirely different (the ones shown above are for
identical pumps) performance curves? The best answer, as usual,
H System 1 System 1+2 will qualify you for a free ticket to attend our Pump School
System 1 session.
200
P&S
200
Dr. Nelik (aka Dr. Pump) is president of Pumping
Machinery, LLC, an Atlanta-based firm specializing in
100 100
pump consulting, training, equipment troubleshooting,
and pump repairs. Dr. Nelik has 30 years experience in
pumps and pumping equipment. He has published over
fifty documents on pump operations, the engineering
Q aspects of centrifugal and positive displacement pumps,
Graph (c). (1) pump against (2) system branches. Method of and maintenance methods to improve reliability,
construction: instead of combining pump curves, add flows (at increase energy savings, and optimize pump-to-system
constant head) for systems (can be more then two). Intersection operations. With questions, comments, or to attend his
of the resultant system curve with a given pump curve produces Pump School, he can be contacted at
the operating point (resultant flow and head). www.PumpingMachinery.com.

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26 APRIL 2007 www.pump-zone.com Pumps & Systems
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