Performance of Centrifugal Pumps

PUMPS: PERFORMANCE and Specific Speed

CONDITION MONITORING Pumps in parallel and series
Pumps in systems
NOTES and WORKBOOK Cavitation, NPSH, Suction Specific Speed
Effect of wear
Ray Beebe 2020 Condition Monitoring methods:
Head-Flow
Shutoff Head
(The sections on performance in these notes are a Indirect Efficiency (Thermometric)
summary only: refer to the many pump texts for Balance leakoff flow
details. Activities are shown in bold - e.g. A) Other factors when investigating poor performance
Let’s test a pump (simulated pump test)

1. Pump performance basics

The four basic quantities in centrifugal pump

performance are Total Head, Power absorbed (or,
just “Power”), Efficiency and Flow. Usually on
works tests, Head, Flow and Power are measured and
Efficiency is calculated from them. Results are
plotted against flow to give curves like the sketch.
(Tolerances of a few percent are allowed given in the
Standard). Manufacturing tolerances also mean that
nominally identical pumps may vary slightly in
performance.

Pump manufacturer catalogues, whether in printed or

online form, usually show characteristics for water at
20°C for a range of impeller sizes in a given casing. To minimize clutter, Efficiency is often shown as
isoefficiency curves or values. See the sample page in the Appendix.

The basic performance Where:

equation is: E = Efficiency, decimal
Q = Flow, m3/s
QgH ρ = Density, kg/m3
E g = gravitational constant = 9.81 m/s2
P
H = Head, metres of liquid pumped (for water at normal ambient
temperature, 1m = 9.8kPa)
P = Power absorbed, W
(Specific Weight is sometimes used in place of ρg)

The Head-Flow characteristic in volumetric terms applies for whatever liquid is pumped. The Power-
Flow curve will however vary with liquid density. An exception is viscosity effects: the H-Q curve
droops with increased viscosity, Power increases. If cold water results are to be compared with tests at
much higher field temperature, efficiency will improve as the kinematic viscosity is less. Hydraulics
Institute gives the correction process.

Positive displacement pumps are usually much smaller, and the characteristic is shown as Flow-Head,
with Flow near linear and dropping slightly as Head is increased and internal leakage increases. Systems
usually have a relief valve to prevent casing or other damage. (See Q-H-P-N curve on page 10).

A What is the power required by a pump B What is the efficiency of a pump delivering 175
delivering 37.5L/s @ 22.7m, if its efficiency is L/s at 64m, absorbing 127.7kW ?
0.815?
For boiler feed pumps, H-Q characteristics are usually in Pressure and Mass flow. H and P both vary with
density.
Pump performance and condition monitoring: Notes and Workbook

QH
With Head in kPa, Flow in kg/s, Power in kW, Efficiency as a decimal: E
P

C A boiler feed pump is tested with water at 140°C, giving 146kg/s, 16300kPa total head (suction 1500, discharge
17800kPa), taking 3650kW. Correct this data to a temperature of 150°C for comparison with the datum
curves.
Using the densities at the mean pressure of water in the pump:
Density at 140 degrees, 8150kPa (average pressure in pump) = 930.2 kg/m3
Density at 150 degrees, 8150kPa = 921.2 kg/m3
Density ratio is 0.9903, so above point becomes 144.6 kg/s, 16144 kPa, 3516 kW.

The characteristics must be corrected for any change in speed. With R as the speed ratio, Flow varies
directly as R, Head as R2, Power as R3. (The Tune Your Pump note has more details).

D A test on a high speed pump at 5400 r/min gives 290kg/s at 11600kPa. Correct this point to compare with the
datum curve at 6000 r/min.

2. Specific Speed

Calculated from the data at Best Efficiency Point, Specific Speed is a family type number that is useful to
indicate the pump characteristics when only the nameplate data is known. Other units can be used, but
using these units gives a number close to that obtained using US units (US gpm, feet).

N Q Where N = rotation speed, r/min

Ns  Q = flow per first stage impeller eye, m3/h
H 0.75 H = head per impeller stage, m

The maximum attainable efficiency relates

to both size and Specific Speed (bottom scale).

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Pump performance and condition monitoring: Notes and Workbook

E All you know about a single stage pump is its F Calculate the Specific Speed of the single-stage
nameplate data: 780 m3/h, 7m head, 980 r/min. What pump with its catalogue curves shown on the last page.
type of pump is it?

3. Pumps in parallel and series

Pumps can be arranged in parallel, where increased flow results with both running (or one can be kept on
standby), or in series to obtain higher pressure (as with multi-stage pumps).

The combined characteristics are obtained in parallel by adding the flow values for selected values of
constant head; and in series, by adding the heads at constant flows. For two identical pumps:

Aux CW Pump
G
45
Plot the H-Q
curve for the 40
combined
performance of 35
two of these
pumps if run in 30
parallel.
Head m

25
20
15
10
5
0
0 10 20 30 40 50 60 70 80 90 100 110 120
Flow L/s

3
Pump performance and condition monitoring: Notes and Workbook

4. The System Curve

A pump must be considered along with the system of piping, fittings and plant items it is to serve. A
system consists of one or more parts:
 Static Head: the difference in free liquid level between suction and discharge (measured on the
plant, or from elevation drawings). Note: this can be negative, such as a pump discharging at a
lower level than an overhead tank on its suction).
 Pressure Vessel Head: (if any) the difference between any pressure acting on the suction and
discharge;
 Friction Head: proportional to Flow squared.

The sketch shows how these are combined to give the system curve.

Note that the static head and/or pressure vessel head may not be constant with flow.

To obtain the combined curve for systems in parallel and series, the same rules apply as for pumps. Free
software such as epanet is available for complex networks.

5. Operating or duty point

Where the system curve and the pump (or combined pumps) curves intersect gives the operating point.

Designers aim to have this within range of the Best Efficiency Point. However, pumps wear and systems
can change (erosion, corrosion, buildup in pipes, etc.)

Note that two pumps in parallel do not give twice the flow to a system. The extra flow available gets
lower as friction losses increase: sketch this effect on the diagram.

60

50

40 pump 1
Head (m)

pump2
30 System
Both pumps
20

10

0
0 50 100 150 200 250 300 350 400 450 500 550 600 650 700
Flow (cu.m/h)

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Pump performance and condition monitoring: Notes and Workbook

H
A multi-stage pump supplies water through
an agitator nozzle in an ash pit. It kept
tripping on high motor current, so was
removed and overhauled. On return, it still
tripped.

A test was run using pressure gauges and

flow meter. The test points are shown.

Can you explain what has happened?

Example- how to apply pump CM by performance analysis

Sketch along with Ray:
I On the diagram for the pump on
Two pumps in parallel (one usually spared)
page 3, plot the operating point
Pump inlet and outlet pipe diameters are the same
for one pump in service. When Pressure gauges are at the same level
new, running unthrottled, suction Water levels stay constant.
head is +2m, discharge head 1m water = 9.8kPa (20°C)
32m.

Plot the operating point when Total

both pumps are run and a flow of Static
88L/s is measured. Head
Plot the zero flow point, then
draw the system curve through Pressure
the three points (obtained by Vessel
test). Head =
10m

6. Cavitation and NPSH

If the pressure of the liquid at the entry impeller drops below its vapour Water properties
pressure, vapour bubbles form – i.e. localised boiling of the liquid occurs. Temp Density Vapour
3
The vapour bubbles implode and can severely damage metal surfaces. °C kg/m pressure
So, cavitation must be avoided. m
0 999.8 0.06
 NPSH-R: Net Positive Suction Head Required: energy required 5 1000 0.09
by a pump at its inlet to prevent Cavitation. It is a function of 10 999.7 0.12
pump design and shown on catalogue curves, as NPSH-R vs 15 999.2 0.17
Flow, or as in the Appendix, noted on the H-Q curve 20 998.3 0.25
25 997.1 0.33
 NPSH-A: Net Positive Suction Head Available: function of system 30 995.7 0.44
design on suction side of pump. If this exceeds what the pump 35 994.0 0.58
requires, with a margin, then cavitation should not occur. 40 992.3 0.76
45 990.2 0.98
With all items expressed as Head of liquid, NPSH-A is calculated from: 50 988.0 1.26

Atmospheric pressure + Static Lift (or - Static Suction Head, if liquid level is above pump
centreline) – Vapour Pressure – Friction losses in suction piping.
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Pump performance and condition monitoring: Notes and Workbook

J
Calculate the NPSH-A for the
system shown at flow of 60L/s.
Flow velocity varies through the
system: V = Q/A.

HL = K v2/2g

K values for fittings:

Foot valve: 15

45° bend: 0.22

Reducer: 0.2

Pipe friction loss is 2m/100m

Is this OK for the pump on the last

page?

The Suction Specific Speed is also used: the same formula as before applies, but with Q in m3/s, and
NPSH-R in place of H. Hydraulics Institute advise that over 175 the probability of repeat installation
failures increases exponentially. Above 180, sustained flow should not be below 85% of BEP.

7. Effect of wear inside a pump

Some liquid from the discharge

of an impeller recirculates to its
suction through the sealing
(wearing) rings. Increased wear
moves the Head-Flow curve
towards the zero flow axis.
Experience shows that the rate
of wear is close to linear
(Beebe, 2004).

Some of the power taken by the

pump is wasted, so efficiency
reduces.

Impeller wear on the outer diameter on the vanes results in a smaller impeller.

Casings can also erode, and thickness can be measured from the outside using NDT.

8. Modifying a pump to change performance

To improve performance, impellers can be underfiled, thus varying the exit angle. The volute can be
chipped to remove metal at the throat. Diameter can be reduced by machining the vanes (see separate
note on tuning a pump). A different impeller of same diameter but wider or with more vanes is another
possibility.

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Pump performance and condition monitoring: Notes and Workbook

9. Condition Monitoring by Head-Flow

Test measurements of Head and Flow at around the normal duty point are sufficient.
Head is measured with pressure gauges or transducers at pump suction and discharge flanges, where
tapping holes are usual. For water at low pressures, a simple manometer made of clear precision plastic
tubing open to the atmosphere works well.

Head is referred to the pump centreline. If the suction and discharge tappings and instruments are not at
the same level (based on centre of the scale for gauges), allowance must be made for liquid heads in the
tapping lines. If the instrument is below the tapping, then it will read too high, and the static liquid leg
must be subtracted from the reading, and vice versa.

Pump suction pressures are often below atmospheric, and the instrument connecting piping is probably
filled with vapour (air which un-dissolves from the liquid) rather than liquid. The static leg of vapour is
negligible. If in doubt, use clear plastic piping, or position the instrument at pump centreline. Tapping
lines should be bled to ensure they are filled with liquid or vapour, as the case may be. To check
transducer sensitivity and contents of the instrument line, lower the transducer a metre and check that the
reading changes by this amount.

Use of quick-connect couplings speeds connection of test gauges or transducers where the liquid is not
hazardous.

Sensors should be calibrated using a deadweight tester before and after the test. A curve of calibration
correction against reading can be drawn to interpolate. Calibration at several points spanning the range
expected on test is more useful than over the full range of the instrument. If excessive hysteresis is
observed, then the instrument should not be used.

Tappings in the side of the pipe measure the line or static pressure, and if the pipe bore diameters there
differ greatly the velocity head must be added to obtain the total head. Often operating pressures are
much higher in proportion and velocity head can t be neglected. For condition monitoring, repeatability
is essential and provided the total head is always obtained in the same way, velocity head can be
neglected.
[Velocity ] 2
Velocity Head, in metres, is calculated from:
2g

The Total Head is the difference between the total heads at pump discharge and suction.

Field tests may not give the same values as that measured at works tests where Standard conditions
require pressure measurements made 2 pipe diameters away from the pump flanges (to avoid any
recirculation effects) and four tappings around the pipe, each with its own isolating valve, and connected
by a piezometric ring. On a 22 m³/h pump where both types of pressure tappings were used, the head
was 10% higher and efficiency 5% higher using flange tappings. (Yedidiah, 1996). In critical cases such
as when disputing guarantee performance, the special tappings would be needed.

When investigating the matching of a pump to a system, any such effects would affect both pump
performance and system equally, and this refinement can be ignored. For condition monitoring, this
effect would be constant with time, and can also be ignored.

Speed must be measured for variable speed pumps with a tachometer, and data corrected to a datum speed
using the affinity laws. Speed may vary significantly on a large constant speed pump if voltage changes.

Flow (or Capacity, Discharge) can be measured repeatably for condition monitoring on most pumps with
a portable ultrasonic or other non-intrusive flowmeter, which clamps on the outside of a straight section
of suction or discharge pipe. These meters give the average velocity of flow, so any bore deposition must
be allowed for in determining the pipe bore diameter.

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Pump performance and condition monitoring: Notes and Workbook

Where available, the flow elements of permanently installed flowmeters can be used. Care must be taken
when connecting in parallel with permanent instruments, as a local pressure drop may trigger pump an
alarm or minimum flow protection, if fitted.

In flanged pipes, an orifice plate may be possible, installed at a joint. Tappings are welded at distances
from the orifice plate of one pipe diameter upstream, half a diameter downstream (called D and D/2).

Repeatable results may be obtained for condition monitoring even without the full lengths of straight pipe
required by flow standards such as ISO5617-1:1997. The units can be volumetric (m3/h, or L/s) or as
mass flow (kg/s). The basic equation for orifice plates and other differential pressure producing devices
is:
Differential pressure
Flow (volumetric )  kd 2
Density

The grouped constant k includes any conversion constants, etc. This can be simplified if the temperature
of the liquid does not vary much from ambient, to:
Flow (volumetric)  k 2 Differential pressure

Included in the grouped constants above is the discharge coefficient. At low flows, this may no longer
be constant, as it increases below a certain Reynolds Number.

If the system includes a tank, timing of the depth (volume) change as it fills or empties can be used.
Tanks may have a chamber for level sensors to give a settled level unaffected by surges of the liquid.
An alternative, also useful for closed tanks, is a manometric level gauge.

Complex pumps may have separate sealing flows into and/or from their shaft glands that bypass the pump
flow measuring point. Usually these are very small in comparison and variations from design may be
neglected for condition monitoring. For critical pumps, separate gland sealing flow metering may be
justified, particularly if the glands can be repaired without dismantling the complete pump.

Each case must be examined to ensure that any minimum flow leakoff valve leakage or axial thrust
balance device flows are properly allowed for in measuring flow through the pump.

Withdrawable pitot tubes are another device which can be used on lower pressures. These are installed
when required through a gate valve in the side of the pipe and sealed by a suitable gland fitting. Note that
the pressure inside the pipe acts to force the tube out, so a restraining system is essential. The
Annubar™ multi-point device is one type, with high accuracy.

A single point double-tip tube can also be made and used (Beebe, 1995). If the flow is not expected to
change significantly, a traverse across the pipe at the Standard positions can relate the centre velocity to
the average. Future tests can then be made with centre measurements only. The flow can be found by
multiplying the average velocity by the pipe cross-sectional area, using consistent units.

If required for motor drives, power is best measured with a test kWh meter, or the two-wattmeter
method, which can however be expensive to arrange. Current and potential transformers must be
identified and their characteristics known.

For 3-phase motors, power usage of a motor in Watts = 3 ×Volts × Amps ×cos For single phase,
power is Watts = Volts × Amps ×cos

To obtain the Power absorbed by the pump, the motor efficiency and the efficiency of any gearbox or
fluid coupling (from works test data) must be taken into account.

8
Pump performance and condition monitoring: Notes and Workbook

For routine condition monitoring, it is worth seeing if a repeatable indication can be given from a panel
ammeter, and using system volts. This is however likely to be crude and of limited use.

K Return to the plot on page 3. After some service, a test on Pump #1 gives flow of 54 L/s @ a total
head of 29m. What has happened?
L Later with both pumps in new condition in the scenario of page 3, operators report that both pumps
must be run to obtain the required flow. Your test gives 60 L/s @ 40m. Plot this point and decide
whether a pump needs overhaul.

9. Shutoff Head

Low energy pumps can be run at shutoff

(i.e. dead headed) for a short time. These
results were obtained on a wastewater
pump where flow could not be measured.

Overhaul restored the performance.

10. Indirect Efficiency measurement

(Thermometric)

Hydraulic inefficiency in a pump converts into heat, so if the liquid temperature rise is closely measured,
the efficiency can be found. This is only a degree or two. For all but small pumps, mechanical losses are
negligible by comparison.

% Efficiency for pumps on water at up to 54°C is given by this empirical formula, which includes a
correction for the isentropic temperature rise which occurs as a result of pressure increase, not from
inefficiency (Total Head is in kPa, temperatures in °C):

100
Temp rise
[1 0.003 ( Inlet temp 2)  4160 ]
Total Head

Commercial devices use combined temperature and pressure sensors installed through gate valves 2
diameters from pump suction and discharge flanges. Measurements of motor input voltage, current and
calculation of motor losses enable power output to be found and then the flow calculated.

11. Balance valve leakoff flow

Multi-stage pumps of the ring section type have the impellers facing towards to suction, and the resultant
thrust can be balanced by enabling some of the last stage exit to flow through an annular space and act on
a balance valve or drum.

As wear proceeds in this space, leakoff flow increases. It is likely that wear will also have occurred on the
wearing rings. The leakoff line is small and results from a pump with a permanent flow meter are shown.

9
Pump performance and condition monitoring: Notes and Workbook

12. Other factors when investigating poor performance

Consider these as well as the previous issues:

 Pump running backwards (dc motors) – still pumps but very poorly.
 Double entry impeller installed wrong way round – still pumps but poorly (vanes become forward
curved).
 Passing isolating valves such that one pump of two in parallel sends water in reverse through the
standby one, rotating it in reverse.
 Poorly matched “identical” pumps to a system that deadheads one when run in parallel.

M The AJAX pump (details in the catalogue on last page) was installed with an
impeller of 258mm diameter. It has just returned from overhaul at a reliable
Let’s test a pump workshop. A new impeller and wearing rings were installed, yet the pump does
not supply the required flow. You are to run a H-Q test, unthrottled, and compare
the test point with the only data available- the catalogue curve.

Also plot the static head and sketch the system curve. What do you conclude?
The test sheet is given on page 12.

Performance characteristics of
positive displacement pumps are
shown differently to those for
centrifugal pumps. The Flow (i.e.
Capacity) decreases as discharge
pressure increases – internal
recirculation or tip leakage increases
at the higher pressure.

12. References and resources (just some)

Europump.org – several excellent guides. Hydraulics Institute pumps.org
Pump Industry Association – Australian Pump Technical Handbook
Beebe (2004) Predicting maintenance of pumps using condition monitoring Elsevier UK

10
Pump performance and condition monitoring: Notes and Workbook

Beebe (2012) Tune your pump to match the system and save money and the environment (Technical
Note)
ISO 5617:1997 Measurement of fluid flow by means of orifice plates, nozzles and venturi tubes inserted
in circular cross-section conduits running full
Yedidiah, S (1996) Centrifugal Pump Users Guidebook Chapman & Hall ( and others by Palgrave,
Karassik, Stepanoff, Shiels, Bacchus, Mackay, Bloch, etc.)

World Pumps magazine www.worldpumps.com

Hydraulics Institute (see Tip Sheets, etc.) www.Pumps.org www.PumpsLearning.org
Pump System Improvement Modelling Tool (PSIM) www.PumpSystemsMatter.org
Pumps & Systems magazine http://pump-zone.com/
Lots of free stuff http://www.pump-flo.com/
Same again- and FAQs, examples http://lightmypump.com/
US Dept of Energy: Pumping System Assessment Tool http://www1.eere.energy.gov/industry/bestpractices/
(PSAT) (free) (search under “Pumps”)
Texas A&M University – Turbo Labs http://turbolab.tamu.edu/resources/default.aspx
AS2417-2001 (Pump testing- same as ISO 9906-1999) ISO13709 :2003 (API 610)

ANSWERS to activities

A 10.2kW

B 86.3%

C This is self-contained
D Speed ratio is 6000/5400 = 1.111

Mass flow corrected is 290 × 1.111 = 322 kg/s.

Head (pressure really) corrected is 11600 ×

(1.111)2 = 14320kPa

E Specific Speed is 6360, so it is a Mixed-Flow pump

F Specific Speed is 2681 , typical for a radial flow pump (remember to use Q in m3/h)

G We shall discuss how the system curve is obtained = Static Head + PVH +kQ 2

H The pump H-Q points are consistent with extrapolation of the curve, so the pump condition is fine. The
system has reduced in resistance, and the pump is drawing more power than the motor rating, so the motor
trips. The nozzle at the end of the pipe had worn off.
I We will discuss this in the session
J NPSH-A calculates at 4.08m. At 60L/s, the pump needs 2.3m (see pump curve) , so there is adequate margin.
K What do you decide from the test point? We will discuss this in the session.
L Same as for K
M We will show a video of the test and note the Head and Flow readings on the test sheet , calculate and plot the
results. We will also find the system curve. Then we will discuss.
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Pump performance and condition monitoring: Notes and Workbook

FLOW Q Measured with “Annubar” pitot Test pressures are

tube in pipe. measured at pump flanges.

“Eagle Eye” meter Bore diameters at flanges:

supplied with Suction: 200 mm,
Annubar
Discharge: 150mm.
Reading % × 0.6 Suction pressure gauge is
% L/s at pump centreline level

Discharge gauge is 0.17m

above centreline

(Difference in water
levels, suction to
(Flow equation given by OEM from discharge, is 12.5m)
Lab calibration)

Head at suction
Suction Calibration Suction Static Suction Static leg Corrected Velocity Velocity Head Total
pressure correction pressure Head (measured) Static at Suction at Suction Suction
reading (test sheet) corrected (calc’d) (gauge is at Suction Vs Vs²/2g Head
pump Head (Calc’d) (calc’d) (includes
centreline) velocity
head)
Test gauge -0.2 kPa ÷ 9.8 0 Q/As A
kPa kPa kPa m m m m/s m m
0
0

EXAMPLE of head calculation (shown for suction):

Say the flow is 70 L/s. With the diameter of 200mm at the suction measuring point, pipe area is
πd²/4 = π 0.2²/4 = 0.03 m².
Therefore velocity = Q/As [units: m3/s and m²]= (70 ÷ 1000)/0.03 = 2.33 m/s).

Test suction pressure reads –19.8kPa. Corrected pressure = (–19.8 – 0.2) = – 20.0kPa;
Static leg here is Nil, as suction gauge centre is at pump centreline level, so Static Suction Head =
– 20.0 ÷ 9.8 = –2.04m

But this pressure does not include that due to flow, so need to add on Velocity Head = V²/2g [g = 9.8]
= 2.33²/(2 ×9.8) = 0.277m, so
Total Suction Head = –2.04 + 0.277 = –1.763m

Head at discharge
Discharge Calibration Discharge Static Static leg Corrected Velocity at Velocity head Total
pressure correction pressure Discharge (measured) Static discharge - discharge Discharge TOTAL
reading (test corrected Head Discharge Vd Vd²/2g Head HEAD
sheet) (calc’d) (gauge is Head (calc’d) H
above pump
C/L)

0 kPa ÷ 9.8 +0.17m B B–A

kPa kPa kPa m m m m/s m m
0 +0.17m
0 +0.17m
Calibration error on this instrument is nil.
Note: Velocity head and static leg are negligible for high pressure pumps.

12
 Pump Test and System details

Pump performance and condition monitoring: Notes and Workbook

Supply to
flow test Constant Head tank
rig
(isolated
for pump
test)

Flow Overflow
Pressure gauge reads 11.0m meter return to
sump
Its centreline is 0.82m from
floor PG Flow control
valve

Ajax Non-return
valve
pump

Sump – water level

Non-return 0.68m below floor
valve (Foot
valve)

Static Head for the system is

the difference between free
liquid level at suction and
discharge =

NPSHA at test (from Page 5):

Atmospheric pressure + Static Lift (or - Static Suction Head, if liquid level is above
pump centreline) – Vapour Pressure – Friction losses in suction piping.

With Suction Gauge reading available, NPSHA = Atmosphere + Gauge Reading (as m)
+ Static Leg to gauge + Velocity Head – Vap pressure

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Pump performance and condition monitoring: Notes and Workbook

14