By Allan R. Budris, P.E.
Any serious pump energy cost reduction effort should start with the development (confirmation) of the true current pumping system “Head-Capacity” curve, as pointed out in my January 2008 Column. The true system head-capacity curve not only permits the accurate determination of the current pump operating conditions, but it is also required to establish realistic potential energy cost savings for optional improvement actions.
As part of the design of most pumping systems, the initial head-capacity curve is normally calculated, based on either “as-new”, or maybe 10 year old, pipe and fittings losses. However, as piping systems age they may not follow these theoretical friction loss estimates, which can push the pump to higher or lower flow rates then planned. A field test of the pump head at one or more measured flow rates can help determine the actual, current, pump and system H-Q curves.
A pump field test should include both pump suction and discharge pressure measurements (with a minimum of two pipe diameters of straight pipe in front of the gauges), along with sizes of the suction and discharge pipes (at the pressure gauge connections). Further, the heights of the suction and discharge gauges, with respect to the center line of the pumps, should be determined, since all pressure measurements must be adjusted to the pump center line. What should ultimately be measured is the total head developed by the pump, between the pump suction and the pump discharge. Total head is comprised of three components: Static Pressure (head), Elevation Head, and Velocity Head. The formula for the Total Head Developed by a pump is:
HPump Total = (pd – ps)*2.31/S.G. + (hvd – hvs) + (Zd – Zs)
Where:
p d = Discharge gauge pressure (psig)
p s = Suction gauge pressure (psig)
h vd = Discharge velocity head, V d2/2g (feet)
h vs = Suction velocity head, V s2/2g (feet)
V d = Discharge pipe velocity (feet/second)
V s = Suction pipe velocity (feet/second)
g = Acceleration due to gravity (32.2 feet/second 2)
Z d = Elevation discharge gauge distance above pump center line (feet)
Z s = Elevation suction gauge distance above pump center line (feet)
S.G. = Liquid specific gravity (cold water is 1.0)
Ideally, the pump field (total head) data should be taken at both the average and full open throttle valve settings. The accuracy of these measurements is only as good as the accuracy of the gauges, so (if possible) calibrated pressure and flow gauges should be used. Field bourdon type pressure gauges are notoriously inaccurate. See reference number 1 for more details on pump testing.