EUROPEAN GUIDE TO PUMP EFFICIENCY FOR SINGLE STAGE CENTRIFUGAL PUMPS

Purpose of the Guide

Pump types and duties

This Guide should only be used for single stage centrifugal pumps handling clean water at up to 95C. Pump types covered are: End suction pumps having their own bearings. End suction close coupled pumps, with the impeller on the motor shaft. Double entry pumps having an axially split casing.

his guide is for anyone wishing to buy or select pumps and save

money. The aim is to help you choose a pump of good efficiency. This will reduce your energy costs. In some cases the saving from just one additional point of efficiency can pay for your pump. We hope this Guide will also reduce the energy used across the EU, benefiting everyone through a better environment.

The applicable ranges of flow and head are shown on Figs 1 and 2 for pumps running at nominally 2900 and 1450 rpm.

Figure 1: Range coverage at best-efficiency duties at 2900 rpm.

1000 ESCC ESOB DESC End Suction Close Coupled End Suction Own Bearings Double Entry Split Casing

Head (m)

96 kW 100 ESOB DESC

200 kW

23 kW

ESCC 1.4 kW 10 10 2.5 kW 100 Flow (m /h)

3

1000

10000

Figure 2: Range coverage at best-efficiency duties at 1450 rpm.

1000 ESCC ESOB DESC End Suction Close Coupled End Suction Own Bearings Double Entry Split Casing

Head (m)

680 kW 100 DESC 20 kW 67 kW ESCC ESOB 7.4 kW

10 10 2

1.2 kW 100 Flow (m3/h) 1000 10000

EUROPEAN GUIDE TO PUMP EFFICIENCY FOR SINGLE STAGE CENTRIFUGAL PUMPS

Method used for producing the efficiency plots

Performance curves published in manufacturers catalogues have been used to produce six plots (Figs 3 to 8). The upper pump efficiency line on each plot shows the Catalogue mean of best-efficiency points at maximum impeller diameter, after correcting for pump head. The lower line is an average of efficiencies for pumps typically selected for flows across the range, which are not always operating at best efficiency point or maximum impeller diameter (Ref 1). The two lines divide the plot into three areas:

Optimum efficiency selections: high efficiency pumps operating at or close to the best efficiency point Efficient selections: pumps which probably have a reasonable best efficiency but, because of standard pump ranges, may have been quoted away from BEP (Best Efficiency Point) Lower efficiency selections: selection in this area should only be accepted if other parameters override (such as very low NPSH, pump operating with short run times, spares inventory minimisation)

85 80 75 Pump efficiency + C (%) 70 65 60 55 50 45 40 35 30

90m 70m 50m 40m 30m 20m

50 Optimum efficiency selections Efficient selections 45 40 35 30 25

Head
130m 110m

Figure 3: Efficiencies of end suction pumps with their own bearings at 2900 rpm. Efficiency correction = C

Lower efficiency selections

20 15 10 5
20m

40

50

60

70

80

0 90 100 110 120 130 140 150 160 170 180 190 200 Pump flow (m3/h) 50

90 85 80 Pump efficiency + C (%) 75 70 65 60 55 50 45 40 20

30m 20m 15m 10m

Optimum efficiency selections

45 40 35 Efficiency correction = C

Efficient selections

Figure 4: Efficiencies of end suction pumps with their own bearings at 1450 rpm.

Lower efficiency selections

30 25 20

Head
50m 40m 15m 10m

15 10 5

60

100

140

180

220

260

300

340

380

0 3

Pump flow (m3/h)

 EUROPEAN GUIDE TO PUMP EFFICIENCY FOR SINGLE STAGE CENTRIFUGAL PUMPS

How to use the efficiency plots:

1. Decide which type of pump you want. 2. Choose the flow and head at which you would like maximum efficiency. 3. Get efficiency quotes from manufacturers (or use published information). 4. Check that the chosen flow and head are within the ranges of Figs 1 or 2. 5. Enter your chosen flow and head on the plot that suits the quotes (Figs 3 to 8). 6. Read correction factor C on the right-hand axis. 7. Add C to the efficiency that has been quoted.

8. Plot (quoted pump efficiency + correction C) at your chosen flow. If the point lies in the Lower efficiency selections area, seek higher efficiency quotes. If the point lies in the Efficient selections area, you have a pump which may well have a reasonable best efficiency but, because of standard pump ranges, has been quoted away from BEP. You should therefore seek higher efficiency quotes, to see if you can get a pump with the BEP closer to your operating point. If the point lies in the Optimum efficiency selections area, you have been quoted a pump with high best efficiency and you are operating close to BEP and you are unlikely to improve on this selection.

Figure 5: Efficiencies of end suction close coupled pumps at 2900 rpm. Pump efficiency + C (%)

85 80 75 70 65 60 55 50
Head

60 Optimum efficiency selections Efficient selections Lower efficiency selections 55 50 45 40 35 30 25

130m 110m 90m 70m 20m 50m 40m 30m 20m

45 40 35 30

20 15 10 5

0 25 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 Pump flow (m3/h) 90 85 80 Pump efficiency + C (%) 75 Efficient selections 70 65 60 55 50 45 40 30 4 35
10m 20m 15m

Figure 6: Efficiencies of end suction close coupled pumps at 1450 rpm.

50 45 Optimum efficiency selections 40 35 30

Head
50m 40m 30m 25m

Lower efficiency selections

25 20 15 10 5

40

45

50

55

60

65

70

75

80

85

90

95

0 100

Pump flow (m3/h)

Efficiency correction = C

Efficiency correction = C

EUROPEAN GUIDE TO PUMP EFFICIENCY FOR SINGLE STAGE CENTRIFUGAL PUMPS

Important note: Although a quoted low efficiency may be due to poor pump quality, it is more likely to be due to your chosen duty not coinciding with that pumps best-efficiency point. Your flow may be below or above the optimum for that pump. Your

head will probably require a reduced diameter impeller. A survey has suggested that you are unlikely to receive more than one quote in five in the Optimum efficiency selections area.

Worked example:
Chosen pump type: Chosen duty for maximum efficiency: Quoted pump performance: End suction with own bearings. 80 m3/h at 110 m. 60% efficiency at 2900 rpm. (Check materials, suction performance, etc, are satisfactory) From Fig 1, yes. From Fig 3: C = 14. Plot on Fig 3: Pump Efficiency + C = 60 + 14 = 74%. Fig 3 suggests that an additional 3 points of efficiency or more is possible. Seek further quotes.

Is chosen duty within ranges covered:

Action:

90 85 80 Pump efficiency + C (%) 75 Lower efficiency selections 70 65 60 55 50 45 40 130

Head
150m 130m 110m 90m 70m 50m

50 Optimum efficiency selections Efficient selections 45 40 35 30 25 20 15 10 5 170 190 210 230 250 270 290 310 330 350 370 390 0 Efficiency correction = C

Figure 7: Efficiencies of double entry axially split casing pumps at 2900 rpm.

150

Pump flow (m3/h) 95 90 85 Pump efficiency + C (%) 80 Lower efficiency selections 75 70 65

80m

50 Optimum efficiency selections Efficient selections 45 40 35 30

Head
140m 120m 100m 15m 60m 50m 40m 20m 40m 30m

Figure 8: Efficiencies of double entry axially split casing pumps at 1450 rpm. Efficiency correction = C

25 20 15 10 5

60 55 50

30m 20m

45 100

200

300

400

500

600

700

800

0 900 1000 1100 1200 1300 1400 1500 5

Pump flow (m3/h)

 EUROPEAN GUIDE TO PUMP EFFICIENCY FOR SINGLE STAGE CENTRIFUGAL PUMPS

Correction of efficiency for pump head

Correction C, as shown on Figs 3 to 8, is based on pump flow, head and speed. It is actually a correction for pump Specific Speed. Pumps of relatively low head and high flow (high Specific Speed) or high head and low flow (low Specific Speed) lose efficiency due to unavoidable secondary hydraulic losses. Within Ref 2 there is a curve to allow efficiency correction for Specific Speed. This is actually the correction proposed by Anderson (Ref 3). Alternative curves to correct for Specific Speed can be derived from Ref 4 and Ref 5. None of these curves appear to provide an optimum correction for the published manufacturers data analysed for this Guide. We have therefore chosen to use an intermediate Specific Speed correction curve, which produces the minimum scatter of the points plotted. There is no strict theoretical justification for this approach but we believe that it serves well for the purpose for which this Guide is intended. (Further information can be found in Ref 6.)

A well-documented guide has been published by Hydraulic Institute and Europump (Ref 7). The guide explains how the operating costs of a pumping system are influenced by system design, and shows in detail how to use an LCC analysis to estimate these costs. Using the recommendations of the guide, you should take into account not only the initial investment cost, but also all the other costs and expenses of operating the system during its projected life.

Basic principles of choosing a pump

The fundamentals of pump selection are covered in Appendix 3 of Ref 6, together with notes on the basics of centrifugal pump characteristics, reducing impeller diameter, reducing speed, and the effect of wear.

Efficiency plots used in this Guide compared to other sources

For practical reasons it has only been possible to source a limited amount of data to produce the plots in this Guide. To assess how meaningful the results are, it is useful to compare them with other sources. The best efficiencies (corrected to optimum Specific Speed) for end suction pumps having their own bearings at 2900 rpm are plotted in Fig 9. The mean of these points is marked Catalogue mean. Additional curves (all at optimum Specific Speed) are derived as follows: Hydraulic Institute Fig 1A (Ref 2). Anderson Fig 7.3 (Ref 3). Maximum practically attainable (EUROPUMP) - Figs 7 to 10 (Ref 4). Theoretically attainable (EUROPUMP) - Using Figs 7 to 10 of Ref 4 (Ref 5).

Loss of pump efficiency with time

A pump of high efficiency is of little value if the efficiency falls rapidly with time. You can minimise this risk. Choose materials carefully, particularly for wear rings. Avoid high and low flow operation in relation to your chosen duty. Ask for cast iron casings to be protectively coated if the water is known to cause serious roughening due to corrosion.

Life Cycle Cost (LCC)

It is likely that the design of the pumping system and the way the pump is operated will have a greater impact on the energy consumption than the pump efficiency alone. You should carry out an LCC analysis to compare different technical alternatives of designing, operating and maintaining a pumping system. The LCC represents the total expenses to purchase, install, operate, maintain and repair a pumping system during its projected life. Down time and environmental costs are also considered.

From Fig 9 we deduce that the Catalogue mean curve is suitable for use in this Guide. The Hydraulic Institute ANSI/API curve is low, particularly at low flows. This is probably mainly due to the use of relatively large wear ring clearances, as required for pumps in special materials or to meet the American Petroleum Institute (API) Standard.

EUROPEAN GUIDE TO PUMP EFFICIENCY FOR SINGLE STAGE CENTRIFUGAL PUMPS

References
1. Evaluation of efficiency values considering the effect of pump size modularity, Stoffel, B., Ludwig, G., and Meschkat, S., Technical University of Darmstadt, 2002. 2. Efficiency prediction method for centrifugal pumps, Hydraulic Institute, 1994. 3. Centrifugal pumps and allied machinery, Anderson, H.H., Elsevier Advanced Technology, 1994. 4. Attainable efficiencies of volute casing pumps, Europump Guide No. 2, 1999.

5. Theoretically attainable efficiency of centrifugal pumps, Stoffel, B. and Lauer, J., Summary of the final report on the research project for VDMA, Technical University of Darmstadt, 1994. 6. Study on improving the efficiency of pumps, Report produced for the European Commission SAVE, 2001. Available via http://energyefficiency.jrc.cec.eu.int/ motorchallenge 7. Pump life cycle costs: A guide to LCC analysis for pumping systems, Europump and Hydraulic Institute, 2000. (ISBN 1-880952-58-0)

95 Theoretically attainable 90 Pump efficiency at optimum Specific Speed (%) Maximum practically attainable

Figure 9: Comparison of efficiencies of end suction pumps from various sources. Hydraulic Institute Large Pumps

85

80

75

70 Anderson Catalogue mean 65 Hydraulic Institute ANSI/API

60

55 10

20

30

40

50

60

70

80

90 100 110 120 130 140 150 160 170 180 190 200 Pump flow (m3/h)

 EUROPEAN GUIDE TO PUMP EFFICIENCY FOR SINGLE STAGE CENTRIFUGAL PUMPS

This Guide has been produced by a Project Team comprising:

Future Energy Solutions (UK) Project Leader CETIM (France) David T Reeves (UK) NESA (Denmark) University of Darmstadt (Germany) EUROPUMP (membership)

For further information please contact:

European Commission, JRC Dr Paolo Bertoldi DG Joint Research Centre I-21020 Ispra Varese Italy Tel. +39 0332 789299 Fax +39 0332 789992 Paolo.bertoldi@cec.eu.int http://energyefficiency.jrc.cec.eu.int EUROPUMP EUROPUMP Diamant Building BD A. Reyers 80 B-1030 Brussels Tel. +32 2 7068230 Fax +32 2 7068250 secretariat@europump.org

The work was funded principally by the European Commission with additional funding provided by the Project Team. Pump motor system energy efficiency continues through the European Commission through the Motor Challenge Programme; more information can be found at http://energyefficiency.jrc.cec.eu.int/ motorchallenge/index.htm

European Commission. This edition printed May 2003.