A couple of years ago, I wrote an article on "How to read basic pump curves" and what the information

means. Now that we have introduced more "family curves" type sheets there has been some question on
how to read these types of curves. This article will attempt to explain how to read the multiple impeller
curves and use these curves for sizing impellers.

STEP 1: The basic pump curves are no different than reading any other head - flow curve. For a known
head value, follow the head over to the pump curve then drop down to the capacity axis and this will be
the flow rate. What you are trying to figure out here is what diameter impeller is needed to get the
required head and capacity.

STEP 2: The next thing to figure out is what motor is needed to drive this impeller without overloading. To
do this use the dashed horsepower lines. To the right of the horsepower line is overloading and to the left
is non-overloading.

STEP 3: The last thing to determine is at what pump efficiency the pump will operate. Look at the U-
shaped lines and interpolate to get the efficiency.

Now let's try an example using ZM1570, Performance Data for Models 6650-6671 (5-15 BHp 4" discharge
units). For the example we will size a pump for 400 GPM at 54 feet of total dynamic head.

STEP 1: Locate the point of 400 GPM at 54 feet on the pump curve. This point is slightly above the 8.31"
impeller but well below the 8.63" impeller so I would go with an 8.38" impeller to hit the duty point.
STEP 2: Next, draw a new pump curve that passes through the duty point and is parallel to the existing
pump curves. This will give you a close representation of the actual performance the pump will deliver.
Look to see where this curve crosses the horsepower line to the right of the design point. In this example
the pump curve crosses the 10 BHp curve at about 48 feet and crosses the 12.5 BHp curve at about 21
feet. We will not oversize an impeller on a pump if the overload point on the pump curve is greater than
the static head for the system. So for this example, if the static head is greater than 48 feet then we can
use the 10 BHp unit. If the

static head is between 21 feet and 48 feet, use the 12.5 BHp motor. If the static head is less than 21 feet
then use the 15 BHp motor.

STEP 3: Now let's figure the pump efficiency we can expect. The design point is about half way in
between the efficiency lines of 60% and 63%. So, for the design point of 400 GPM at 54 feet, we would
expect about 61.5% pump efficiency.

As you can tell from the above example, we would consider oversizing an impeller on a unit and not
overload the unit due to engineering the right pump for the system. If this were the case we would also
able to provide a more competitively priced unit since pricing is based on motor size (i.e. smaller motors
cost less). The only exception to this rule is a single-phase unit. ZOELLER COMPANY DOES NOT SELL
SINGLE-PHASE UNITS WITH OVERSIZED IMPELLERS because we feel that this will compromise the
life of a single-phase unit.

If you have any questions, please give us a call at 1-800-928-PUMP (78

The key thing to remember when reading a pump curve is all curves are based upon the principle of plotting data
using the x and y axis. With this in mind, the curves typically plotted are head vs. capacity, power input vs capacity,
and pump efficiency vs. capacity. Therefore the constant between each curve is the capacity or x-axis. To determine
the performance data at a particular point, first locate the operating point of the pump. This is the point where the
system head curve crosses the pump’s head vs. capacity curve. From this point move horizontally to the left until you
intersect the y-axis. This will give you the head at which the pump will operate. Next go back to the operating point.
By moving vertically down to the x-axis, you can find the capacity that the pump will operate. Now, at the determined
flow rate, moving vertically to the input power curve intersection, then move horizontally to the kW input y-axis the
appropriate value for motor input can be read. In like manner the pump efficiency can be read by keeping the flow
constant once again. By using this method and Figure 1 the design point is 320 GPM @ 22' TDH. The power input
and pump efficiency are 3.4 kW and 53%, respectively.

Each of the above items is calculated from the performance data obtained when testing a pump. The pump test can
either be done at the factory or in the field with the appropriate equipment. Head, capacity, current, power input, and
voltage are all items that are read by the test equipment. Power factor, motor efficiency, motor input horsepower
(EHp), brake horsepower (BHp), hydraulic horsepower (WHp), total efficiency, and pump efficiency must be
calculated or looked up in tables.
Now that I have thrown out all these terms, what do they mean? The following is a glossary from the SWPA
Handbook and the Hydraulic Institute for the above terms.

• Head - a measure of the pressure or force exerted by the fluid.

• Capacity - the rate of liquid flow that can be carried.

• Current - the amount of electricity measured in amps which is flowing in a circuit.

• Power input - the electrical input to the motor expressed in kilowatts (kW). A measure of the rate at which work is
done.

• Voltage - the potential or electrical magnetic force (EMF) in an electrical circuit.

• Power factor - the ratio of the true power to the volt-amperes in an alternation current (ac) circuit.

• Motor efficiency - a measure of how effectively the motor turns electrical energy into mechanical energy. It is the
ratio of power input to power output.

• Motor input horsepower (EHp) - the power input to the motor expressed in horsepower.

• Brake horsepower (BHp) - the power delivered to the pump shaft expressed in horsepower.

• Hydraulic horsepower (WHp) - the pump output or the liquid horsepower delivered by the pump.

• Total efficiency - the ratio of the energy delivered by the pump to the energy supplied to the input side of the motor.
Sometimes refered to as the ‘wire to water efficiency’.

• Pump efficiency - the ratio of the energy delivered by the pump to the energy supplied to the pump shaft.

In the above terms, motor refers only to the device that drives the hydraulic end; and pump refers only to the
hydraulic end.
Usually most people understand the terms measured by the test equipment but do not understand the calculated
terms and how they relate to each other. First, I’ll give the formulas for the terms then we will look at an example for
the performance curve in Figure 1.

Motor input horsepower (EHp) = Power input (kW) * 1.341

Brake horsepower (BHp) = (2)Motor efficiency * EHp

Hydraulic horsepower (WHp) = [Head (feet) * Capacity (GPM)] / 3960

Total efficiency = (WHp / EHp) * 100%

Pump efficiency = (WHp / BHp) * 100%

1) Found from meter readings.

2) Motor efficiency is usually looked up in a chart from the motor manufacturer.

Now let's look at an example. At our design point of 320 GPM @ 22' TDH the power input and pump efficiency
are 3.4 kW and 53%. From a certified test or using a multimeter after the unit is installed, one can find that the current
is 9.9 amps at 230 volts, 3 phase. The motor efficiency at this point is 73.7%. Therefore,

Motor input horsepower (EHp) = 3.4 * 1.341 = 4.56 Hp

Brake horsepower (BHp) = 0.737 * 4.56 = 3.36 Hp

Hydraulic horsepower (WHp) = [22 * 320]/3960 = 1.78 Hp

Total efficiency = (1.78/4.56) * 100% = 39.0%

Pump efficiency = (1.78/3.36) * 100% = 53.0%

Since we are dealing with so much math, I'll throw in one more useful formula.

Cost to operate for a year = Duty cycle*Power input*Electrical cost ($/kW hour)*Hours in a year

From our example assuming a 25% duty cycle, and 7¢/kWh

Cost to operate for a year = 0.25*3.4*0.07*8760 = $521.2