water & wastewater operation: pipe systems, system curves ... · water & wastewater...
TRANSCRIPT
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Water & Wastewater Operation:
Pipe Systems, System Curves, & Pump Curves
Matt Prosoli
PumpsPlus Inc.
30 Years in Water & Wastewater
BA in Marketing, Michigan State Univ.
MWEA Maintenance Committee 30 years
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If your cow sounds like this
may we suggest the fish.
If your cow sounds like this
then fire up the barbecue.
BUT FIRST---A Public Service Announcement
How to determine if your cow has Mad Cow Disease..
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PUMP PERFORMANCE CURVE DEVELOPMENT
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IMPELLER DISCHARGE
CONFIGURATIONS
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THE DIFFERENCE BETWEEN THEORETICAL AND ACTUAL PUMP CURVES
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These Losses can be reduced by:
• Improving the impeller inlet conditions
•Accelerating the fluid gradually
• Improving casting technology
•Utilizing Double Volutes
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The More we reduce the Shock, Turbulence, Recirculation, and Friction losses, the Higher the
Efficiency.
FRANCIS VANED IMPELLERS
EXTEND INTO SUCTION EYE
TO ACCELERATE FLUID
GRADUALLY.
DOUBLE VOLUTE SERVES TO
REDUCE RECIRCULATION AND
TURBULENCE LOSSES,
BROADENING EFFICIENCY BANDS.
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FLUID IN THE DISCHARGE CHAMBER NOLONGER IMPACTS EFFICIENCY
COMPENSATED DOUBLE-VOLUTE
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A TYPICAL CATALOG
PERFORMANCE CURVE
POR= Preferred operating range, 70-120 % of BEP
AOR= Acceptable operating range, defined by isobars on mfg. curve
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Positive Displacement Rotary Lobe Pump Curve
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Double Disk Positive Displacement Pump Curve
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Typical Vertical Turbine Performance Curve
Efficiency correction per stage
Performance is per stage and these pumps can have many depending on TDH
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HEAD (PRESSURE)
FEET OR POUNDS. 1 PSI =2.31 FT.
FLOW US GPM (AN AMOUNT OVER TIME)
Q
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A COUPLE OF IMPORTANT TERMS
• BRAKE HORSEPOWER = THE POWER REQUIRED TO DRIVE A PUMP.
• PUMP EFFICIENCY = OUTPUT POWER DIVIDED BY INPUT POWER.
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BHP = (GPM) (TDH) (SG)
(3960) (EFF)
WHERE,
GPM= US GALLONS PER MINUTE
TDH = HEAD IN FEET
SG = SPECIFIC GRAVITY
3960 = “A CONSTANT”
EFF = PUMP EFFICIENCY
IMPORTANT!!!
REMEMBER THIS FORMULA.
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3960 IS A CONSTANT LINKING A
HORSEPOWER (33,000 ft
lbs./min.) TO A US GALLON (8.333 lbs.)
33000 = 39608.33
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TEST DATA
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CALCULATED VALUES
FROM TEST DATA
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TEST CURVE PLOTTED FROM TEST DATA
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AN IMPORTANT POINT!!!!!
At a given speed, with a given impeller diameter:
The pump will perform along its characteristic curve, from run
out to shut off
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Shutoff and Runout
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FLOW CHANGES DIRECTLY AS A CHANGE IN SPEED OR DIAMETER
HEAD CHANGES AS THE SQUARE OF A CHANGE IN SPEED OR DIAMETER
HORSEPOWER CHANGES AS THE CUBEOF A CHANGE IN SPEED OR DIAMETER
PUMP AFFINITY LAWS
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Q
Q
D
DO R
Q
Q
N
N
H
H
D
DO R
H
H
N
N
BHP
BHP
D
DO R
BHP
BHP
N
N
1
2
1
2
1
2
1
2
1
2
1
2
2
1
2
1
2
2
1
2
1
2
3
1
2
1
2
3
PUMP AFFINITY LAWS
IMPORTANT...REMEMBER THESE
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WHEN WE TRIM AN IMPELLER, PERFORMANCE CHANGES IN ACCORDANCE WITH THE AFFINITY LAWS.
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AND AGAIN, AND AGAIN, ...
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As we trim, we can’t expect the efficiency to stay the same,
remember the internal losses.
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As we trim, the turbulence
and recirculation losses (in
particular) increase.
So efficiency is reduced.
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At 3,000 GPM82% at BEP max diameter impeller<70% at min diameter impeller
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Variable speed curves illustrate the flexibility of a pump without changing out impellers.
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WHY WORRY ABOUT NPSH ?
PUMPS DON’T SUCK.
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NPSHNET POSITIVE SUCTION HEAD
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REMEMBER PUMP BASICS
THE FLUID NEEDS TO ENTER THE IMPELLER
BEFORE THE IMPELLER CAN BEGIN ADDING
ENERGY.
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NPSH DEFINES THE
ENERGY AVAILABLE TO
THE FLUID, OR
REQUIRED BY THE
PUMP TO “FORCE” THE
FLUID INTO THE
IMPELLER VANES.
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THERE ARE REALLY TWO “TYPES” OF NPSH
• NPSH(R) IS THE NPSH REQUIRED BY THE PUMP. IT IS A FUNCTION OF PUMP DESIGN. (THIS IS THE NPSH SHOWN ON THE PUMP CURVE.)
• NPSH(A) IS THE NPSH AVAILABLE TO THE PUMP. IT IS A FUNCTION OF THE SYSTEM DESIGN.
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NPSH IS A LITTLE LIKE A CHECKBOOK
• NPSH(R) IS LIKE THE MONEY YOU NEED TO PAY YOUR BILLS.
• NPSH(A) IS YOUR INCOME.
• YOU NEED AT LEAST AS MUCH INCOME AS YOUR BILLS.
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NPSH(A) NPSH(R)
THE “RULE”:
FOR PRACTICAL PURPOSES, FORGET THE
EQUAL SIGN:
NPSH AVAILABLE MUST BE
GREATER THAN THE NPSH REQUIRED.
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NPSH(R)After design, there is little that can be done about NPSH(R).
Chief factors influencing NPSH(R) include impeller eye area, vane inlet design, and the
relationship with the casing.
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NPSH(A)
•THE NPSH(A) IS INFLUENCED BY SEVERAL FACTORS, MANY OF WHICH ARE CONTROLLABLE OR MODIFIABLE.
•THESE FACTORS INCLUDE THE ABSOLUTE PRESSURE, VAPOR PRESSURE, SUCTION PRESSURE, AND FRICTION LOSSES
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NPSH(A) FORMULA•NPSH(A) = H(A) + H(S) - H(VPA) - H(F)
• WHERE
•H(A) = ABSOLUTE PRESSURE
•H(S) = SUCTION PRESSURE (HEAD)
•H(VPA) = VAPOR PRESSURE
•H(F) = SUCTION PIPING FRICTION HEAD
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IT IS IMPORTANT TO REMEMBER THAT IN A
SUCTION LIFT SITUATION, H(S)
WILL BE A NEGATIVE NUMBER.
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ABSOLUTE PRESSURE•THE ABSOLUTE PRESSURE IS THE PRESSURE (ENERGY) ADDED TO THE FLUID BY AN OUTSIDE SOURCE.
•IN AN OPEN SYSTEM, THIS IS THE ATMOSPHERIC PRESSURE.
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ATMOSPHERIC PRESSURE
• 1 PSI = 2.31 FT H20 AT 70OF
= 2.0438 MERCURY INCHES
• 14.7 PSI = 33.9 FT = 30 INCHES Hg.
• (WATCH THE WEATHER REPORT)
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ATMOSPHERIC PRESSURE vs. ALTITUDE
ALTITUDE ABOVE
SEA LEVEL
FEET OF WATER PSIA
0
1000
2000
3000
4000
5000
6000
7000
8000
9000
10000
33.9
32.8
31.6
30.5
29.4
28.3
27.3
26.2
25.2
24.3
23.4
14.7
14.2
13.7
13.2
12.7
12.3
11.8
11.3
10.9
10.5
10.1
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VAPOR PRESSURE OF WATER VERSUS TEMPERATURE
FEET OF WATER PSIA oC oF
0.20
0.29
0.40
0.56
0.78
2.47
6.68
15.87
33.96
66.53
121.04
206.98
334.95
519.75
773.85
0.0686
0.125
0.173
0.245
0.339
1.07
2.89
6.87
14.7
28.8
52.4
89.6
145
225
335
0
5
10
15
20
40
60
80
100
120
140
160
180
200
220
32
41
50
59
68
104
140
176
212
248
284
320
356
392
428
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VAPOR PRESSURE CURVE
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NPSH –SOME
EXAMPLES
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EXAMPLE 1--- OPEN SYSTEM WITH
LIQUID RESERVOIR ABOVE PUMP.
NPSH(A) = H(A) + H(S) - H(VPA) - H(F)
41.12 = 33.9+10-.78-2
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EXAMPLE 2-
OPEN SYSTEM WITH LIQUID RESERVOIR
BELOW PUMP
NPSH(A) = H(A) + H(S) - H(VPA) - H(F)
21.12 = 33.9+(-10)-.78 -2
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SYSTEM CURVES
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START WITH THE SYSTEM
The Pump is Only one Component in the System.
It is Most important in any Discussion to Start With the System.
Without a Thorough Understanding of the System, there will be Little Chance of Selecting the Right Pump
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TOTAL DYNAMIC HEAD
Total Dynamic Head (TDH)= (P2 - P1) x
2.31
Specific Gravity + Z2 + Hfs + Hfd
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REMEMBER THAT THE SYSTEM CURVE REPRESENTS FLOW THROUGH A PIPING SYSTEM AT A GIVEN TIME
•If we change the piping, we change the system curve.
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H1 = ( Q1)1.85
H2 Q2
OR, MORE COMMONLY
(Known as a Standard
‘Second Order’ Curve)
:
(Q2)2= H2
Q1 H1(HEAD WILL CHANGE AS
THE SQUARE OF FLOW)
H1= FRICTION HEAD AT DESIGN FLOW Q1
H2= FRICTION HEAD AT ASSUMED FLOW Q2
SYSTEM CURVE DEVELOPMENT
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WHERE A PUMP OPERATES
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RESULTS OF PART LOADING OR SYSTEM CURVE DEVIATION ON PERFORMANCE
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RUNNING MORE THAN ONE PUMP AT A TIME
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PARALLEL PUMPING
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PUMP PERFORMANCE WITH PARALLEL PUMPING
AT ANY GIVEN HEAD, FLOWS ARE ADDITIVE.
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SERIES PUMPING
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SERIES PUMPING
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PUMP PERFORMANCE WITH SERIES PUMPING
AT ANY GIVEN FLOW, HEADS ARE ADDITIVE.
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COMBINED SERIES AND PARALLEL PUMPING
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COST OF PUMPING
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CALCULATING OPERATING COSTS: (PUMP “A”)DESIGN POINT: 3200GPM @ 160’TDH
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COST PER HOUR OF PUMPING
CPH = (.000189)(US GPM)(TDH[ft])($/KWH)(SG)WWE
WWE= WIRE TO WATER EFFICIENCY
FIXED SPEED WWE= (PE) (ME)
VARIABLE SPEED WWE = (PE) (ME) (DE)
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WHAT’S THE .000189?• ANOTHER CONSTANT!!
1HP = 33000 ft lbs = .746 kW
1 GALLON H20 = 8.333 LBS
.746 =.0001893960 .000189 LINKS A HP TO A
kW TO A FT OF H20 TO A
GALLON
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CALCULATING OPERATING COSTS
ASSUME $0.10 /KWH
ASSUME 92% MOTOR EFFICIENCY
ASSUME 2 PUMPS
ASSUME 24 HRS / DAY
ASSUME 365 DAYS / YEAR
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CALCULATING OPERATING COSTS
ASSUME $.10 / KWH, ME = .92, 24 HRS / DAY, 365 DAYS / YEAR, 2 PUMPS.
CPH = .000189 x 3200 x 160 x.10
.845 X .92
= 9.6768
.7774
= $12.45 / HR / PUMP
x 2 PUMPS x 24 HRS/DAY x 365 DAYS/YEAR
= $218,124 / YEAR
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CALCULATING OPERATING COSTS DESIGN POINT: 3200 GPM @ 160’TDH (PUMP “B”)
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ASSUME $.10 / KWH, ME = .92, 24 HRS / DAY, 365 DAYS / YEAR, 2 PUMPS.
CPH = .000189 x 3200 x 160 x.10
.90 X .92
= 9.6768.828
= $11.69 / HR / PUMP
x 2 PUMPS x 24 HRS/DAY x 365 DAYS/YEAR
= $204,809 / YEAR
CALCULATING
OPERATING COSTS
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THE DIFFERENCE IS SAVINGS
THE DIFFERENCE IN PUMP EFFICIENCY BETWEEN THE 84.5% EFFICIENT PUMP “A” AND THE 90% EFFICIENT PUMP “B” RESULTS IN REAL OPERATING COST SAVINGS
PUMP “A” OPERATING COST = $218,124. / YEAR
PUMP “B” OPERATING COST = $204,809. / YEAR
$ OP.COST SAVINGS = $13,315. / YEAR
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WHAT HAPPENS IF THE
SYSTEM CURVE IS OFF?
Assume friction loss is off by 29% (probable
worst case?!---If we exclude):
Safety factors by suppliers
Safety factors by designers
“As built” differences from design
Mistakes
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RESISTANCE WILL DROP FROM THE EXPECTED 160’
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TO 114’ (71% OF 160’)
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TO 114’ (71% OF 160’ [AT DESIGN FLOW!!])
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TO ?
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PUMP “A” RUNS OUT TO ITS “SECONDARY OPERATING
POINT”, …?
WHAT HAPPENS IF THE SYSTEM
CURVE IS OFF?
(SINCE WE HAVEN’T CONSIDERED ANY OFTHE “SAFETY FACTORS”,
LET’S USE 4600GPM @114’TDH)
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CALCULATING OPERATING COSTS (PUMP “A”) DESIGN POINT: 3200 GPM @ 160’TDH
SECONDARY OPERATING POINT: 4600 GPM @ 114’TDH
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CALCULATING
OPERATING COSTS
CPH = .000189 x 4600 x 114 x.10
.725 X .92
= 9.911.667
= $14.86 / HR / PUMP x 2 PUMPS x 24 HRS/DAY x 365 DAYS/YEAR
= $260,347 / YEAR
ASSUME FRICTION LOSS IS OFF BY 29%. (PROBABLE WORST CASE).ASSUME $ 0.10 / KWH, M.E. =.92, 24 HRS / DAY, 365 DAYS /YR, 2 PUMPS
PUMP “A” RUNS OUT TO ITS “SECONDARY OPERATINGPOINT”, 4600 USGPM @114’TDH.
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• ASSUME FRICTION LOSS IS “OFF” BY 29% (PROBABLE WORST CASE?!)
• PUMPB “B” RUNS OUT TO ITS SECONDARY OPERATING POINT (@114’TDH)
What Happens if the System Curve is "Off"?
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CALCULATING OPERATING COSTS (PUMP “B”) DESIGN POINT: 3200 GPM @ 160’TDH
SECONDARY OPERATING POINT: 4500 GPM @ 114’TDH
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CALCULATING
OPERATING COSTS
CPH = .000189 x 4500 x 114 x.10
.85 X .92
= 9.696.782
= $12.40 / HR / PUMP x 2 PUMPS x 24 HRS/DAY x 365 DAYS/YEAR
= $217,248. / YEAR
ASSUME FRICTION LOSS IS OFF BY 29%. (PROBABLE WORST CASE).ASSUME $ 0.10 / KWH, M.E. =.92, 24 HRS / DAY, 365 DAYS /YR, 2 PUMPS
PUMP “B” RUNS OUT TO ITS “SECONDARY OPERATINGPOINT”, 4500 USGPM @114’TDH.
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OP. COST “A” = $260,347. / YROP. COST “B” = $217,248. / YR.
SAVINGS = $43,248./YR.
(IF LIFE IS 20 YEARS,
OPERATING COST
SAVINGS, THEN, IS
SOMEWHERE BETWEEN$266,300 AND $865,900!!!!)
The Difference Is Savings
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Are There any Questions?