DESIGNERS NOTEBOOK
Pressure-Booster Pump Sizing and Applications
Part 1
Timothy A. Smith, CPD
When pressure in the municipal wa-
ter supply is not sufficient to satisfy
building requirements and water de-
mands, there are three accepted meth-
ods to boost the pressure to an accept-
able level. A hydro-pneumatic tank, a
gravity tank, or a water-pressure boost-
er pump can be used. This installment
focuses on the sizing and application of
pressure-booster pumps and systems.
Smaller applications may only need
a single pump, possibly with a small
hydro-pneumatic bladder tank to
avoid a need for continuous pump
operation. Larger applications may re-
quire multiple pumps, but hydro-
pneumatic tanks may not be required,
because a larger building often has a
continuous demand that justifies con-
tinuous pump operation.
A single-pump application can be
controlled by a combination starter
disconnect with pressure switch. A
multiple-pump system requires control
from an engineered and factory-wired
panel with intelligent and sequencing
control circuitry. In commonly used
terminology, pressure-booster pump
refers to a single-pump combination,
while a pressure booster system is a
factory assembled, multiple-pump
combination. The word system refers
to multiple components (e.g., pumps,
control panels, pipe, valves) pre-engi-
neered in a factory-fabricated and test-
ed assembly. The assembly is custom
fabricated to the exact specifications
set forth by the designer.
For a larger system, specification of
a factory-fabricated, packaged system
is the preferred method. Building and
wiring a system in place from scratch
can easily result in confusion, improp-
er installation, and necessary addition-
al costs.
A packaged system also has the ad-
vantage of a single responsibility source.
A pressure-booster pump with simple
pressure-switch controls is easy to
44 Plumbing Systems & Design Nov/Dec 2003
specify and convey to an installer for water demand for different types of
assembly and construction. When de- building occupancies varies greatly.
signing multiple-pump systems with For instance, 10 water closet flush
controls to monitor water pressures, valves in an office building require a
electrical currents, suction pressures, lower maximum flow rate than, say,
discharge pressures, motor, 10 water closet flush
and speeds, you will find valves in a public school.
the system can become Determination of Current sizing technolo-
very complex from a con- the probable flow gy utilizes a sliding-scale
trol standpoint. It is recom- rate is the most graph, commonly referred
mended that you seek the to as Hunters curve. This
difficult and
advice of a booster-system graph applies more diver-
manufacturer when its controversial part sity to water flow as the
time to write specifications of sizing a water- quantity of fixture units in-
for the control-circuit tech- pressure booster creases. The theory is that
nology utilized for pres- as the quantity of fixtures
sure-booster systems. It is
pump or system. increases, the likelihood
also recommended that of simultaneous use de-
you have an electrical en- creases. The ASPE Research
gineer review all control-wiring dia- Foundation is working on a program
grams and control-panel product data to to study water demand to develop
be submitted with the pressure-booster queuing factors based on building
system shop drawings. type and occupancies. The intention
Sizing of the Research Foundations work is
Two things need to be determined to take the water demand curve,
when sizing a pressure-booster sys- which was originally intended to be
tem: system water demand and sys- applied to every building, and modify
tem pressure demand. Calculating wa- it to more closely model a buildings
ter and pressure demand is not diffi- water demand based on different
cult, but it does require a set of build- building types and occupancies.
ing plans or a site inspection. A site The judgment and experience of the
inspection allows you to count the designer plays an important part, be-
various types of plumbing fixtures uti- cause there can be a wide difference
lized in the building, but you may in water demand between building
need a very long tape measure to de- types. The designer needs to quantify
termine the required static height. Us- all of the various plumbing fixtures in
ing building plans works best, espe- a building in terms of fixture-unit val-
cially if the building in question ues to determine the fixture-units total.
has yet to be built. Figure 1 is an example of demand
weight of fixtures in fixture units. Al-
System Water Demand
ways check your local codes, because
Water demand or flow rate is the
fixture-unit values are not the same in
volume of waterin gallonsthat
the different codes.
needs to be delivered to any part of
Another controversy in establishing
the building each minute of the day.
flow rates is the best way to determine
Flow rate is a very dynamic condition,
the value to apply to fixtures that are
and determination of the probable
not normally used. For example, a
flow rate is the most difficult and con-
service sink in an office building is
troversial part of sizing a water-pres-
normally used by the janitors only at
sure booster pump or system. The
 DESIGNERS NOTEBOOK
Figure 1. Demand Weight of Fixtures night; therefore, the service sink
should not be counted as a fixture in
the total demand. Hose bibbs should
not be counted at 100% of their num-
ber. In a large building, many hose
bibbs may be installed, but few are
operated at the same time.
After the designer has determined
which fixtures to include in the water-
demand calculation, the maximum or
peak-flow rate can be determined.
The total fixture-unit value is obtained
by adding all water-using fixtures that
have normal domestic diversity. The
fixture units can be converted into a
gallons-per-minute (gpm) flow rate by
using the conversion charts illustrated
in Figure 2. The flow demand of all
continuous-use fixtures is then added
to the flow rate established from the
conversion charts. A continuous-use
fixture or piece of equipment does
not have normal diversity; water-
cooled equipment, air-conditioning
cooling towers, lawn sprinklers, and
industrial processes are some continu-
ous-use fixtures or equipment. Any
such fixtures or equipment should be
calculated independently. The com-
bined total figure represents the flow
rate for the building.
A designer with extensive project
experience may apply additional diver-
sity factors to the conversion graphs in
Figure 2 to adjust for different building
types and occupancies. Some pres-
sure-booster system manufacturers
have taken Hunters curve and com-
bined it with their project experience
to develop modified curves for specific
building types and applications. Expe-
rience dictates that the manufacturers
data is more useful than the single
Hunters curve that is supposed to
apply to all building types.
System Pressure Demand
Pressure demand or residual pres-
sure is the pressure of the water, in
pounds per square inch (psi), that
must be supplied to the fixture or de-
vice while flowing the required water
demand. Many fixtures or devices
require minimum inlet pressures to
Reprinted from ASPE Data Book Vol. 2 (2001), p. 123 continued on page 46

Nov/Dec 2003 Plumbing Systems & Design 45


Figure 2. Conversion of Fixture Units to Gallons per Minute (Liters per Second)
Reprinted from ASPE Data Book Vol. 2 (2001), p. 120
operate and function to the engi-
neered specifications. For instance, a
diaphragm-type flush valve needs ap-
proximately 30 psi to operate properly,
delivering the required volume of wa-
ter in a short enough time to develop
velocity sufficient to clean the bowl.
Conversely, an open faucet tap can
operate with minimal pressurebe-
low 10 psi. Inlet pressures are most
critical to plumbing fixtures with me-
chanical mechanisms or pressure-ad-
justing components (e.g., thermostatic
or pressure-balanced shower valves,
flush valves, pressure-sustaining
valves).
46 Plumbing Systems & Design Nov/Dec 2003
DESIGNERS NOTEBOOK
Fixture demand pressures need close
evaluation against the static lift re-
quirements of the system.
The conversion formula of 1 psi =
2.31 ft of static is used to determine
the pressure boost required from a
pump. Calculate the difference in verti-
cal height between the discharge out-
let or pressure-sustaining valve of the
booster pump and the highest served
plumbing fixture or device. This num-
ber represents the height or vertical lift
factor in the system-pressure demand
determination. Then you can divide
the static lift required by 2.31 to obtain
the pressure in psi. Please note that
static pressure and residual pressure
are different (static is without water
flow, and residual is with water flow).
Booster pumps and systems are de-
signed to have water flow. Design
considerations for residual pressures
are calculated with the next factor.
Delivery of 3040 psi at the
most remote fixture is a
good rule of thumb for
most applications.
The friction-loss factor of the calcu-
lation includes not only piping losses
but also losses from valves, fittings,
sensing wells, devices, and bushings.
Bushings are a significant source of
friction loss in domestic plumbing sys-
You should consider three main fac-
tems. Often, bushings are substituted
tors when calculating the water-pres-
for tapered fittings, although the fric-
sure demand for a booster pump or
tion loss through a bushing can be
system:
510 times higher than through a fit-
static height or vertical elevation of
ting, depending on size and flow. To
the highest fixture from the booster
achieve the designed friction loss, it is
friction losses through the piping
important to qualify piping details and
system at the most remote location
specifications as to the types of fittings
the minimum required residual
allowed.
pressure at the highest and most re-
The friction loss graph in Figure 3
mote location.
illustrates the relation among flow,
The most remote fixture may not al-
friction loss, and velocity through
ways be the fixture that dictates the
smooth copper water pipe. It is rec-
minimum required system pressure. It
ommended that velocities be kept
is common to have the most demand-
low, because they are correlated with
ing fixture at a lower elevationin
higher friction losses and more rapid
closer proximity to the booster system.

Figure 3. Pipe Sizing Data (Smooth Pipe)
Reprinted from ASPE Data Book Vol. 2 (2001), p. 139
deterioration of the piping system. To
arrive at an approximate booster size,
you should apply the design criteria
for establishing system water demand,
estimate approximate pipe sizes for
the supply mains, and use Figure 3 to
establish the respective friction/pres-
sure loss. Additional losses through
valves, fittings, and devices will have
to be calculated in the final sizing, but
this approach will help you approxi-
mate the size, configuration, pump
type, and horsepower required. The
Cv method of valve sizing reduces all
variables to a common denominator
called the flow coefficient. A dimen-
DESIGNERS NOTEBOOK
sionless number, it is used to deter-
mine friction losses through various
valve types and sizes based upon the
flow rate. You should refer to the
valve manufacturers product data for
its liquid flow graphs and correspon-
ding Cv factors when you calculate
friction losses and pressure drops
through the systems valves. You can
calculate the exact friction/pressure
loss when the design is 100% com-
plete and you are able to quantify
pipe sizes, pipe lengths, valve sizes
and types, fittings, and devices. Only
slight adjustments to the booster pump
or systems specified performance
Nov/Dec 2003 Plumbing Systems & Design 47
schedule may be needed if conserva-
tive velocities are utilized in the pipe
sizing at the onset.
The minimum required residual
pressure at a fixture is the last factor
of the equation. Delivery of 3040 psi
at the most remote fixture is a good
rule of thumb for most applications.
In most buildings, the diaphragm
flush valve is the most demanding fix-
ture. It requires a minimum of 30 psi.
Pressure-balanced shower valves or
mixing valves require 20 psi mini-
mum. In any case, this designer
would not design a system that could
not maintain a minimum of 20 psi
residual system pressure. Buildings
more than 8 stories in height require
multiple pressure zones, because
there are also maximum allowable in-
let pressures for fixtures and devices.
Most of the model codes recognize 80
psi as a maximum system pressure.
Future articles will discuss multiple
pressure zones, pressure-reducing sta-
tions, and recirculation issues associat-
ed with high-rise building design.
Simply add the three factorsstatic
lift, friction/pressure losses, and mini-
mum required residual pressureand
you have the required delivery pres-
sure of the booster pump or system.
Combine this with the water demand
calculation and you can select a pump
or system. In Part 2, pressure-booster
pump system types, various pump
types, the use of hydrostatic accumu-
lator tanks, the application of multiple
pump systems, and system controls
will be discussed.
Tim Smith is vice presi-
dent, partner, and found-
ing member of Metro De-
sign Associates, Inc., in
Schaumburg, IL. He has
more than 23 years expe-
rience covering all aspects of consulting en-
gineering, specializing in plumbing, fire
protection, and civil engineering. His e-
mail address is tsmith@metrodgn.com.