AFT-Four Quadrant Pump Data - Theory Part 1 PDF
AFT-Four Quadrant Pump Data - Theory Part 1 PDF
AFT-Four Quadrant Pump Data - Theory Part 1 PDF
ABSTRACT
The transient analysis of reverse flow and rotation in pumps has evolved over the years
into modern four quadrant pump waterhammer simulation. Exact characteristics for a
given pump for reverse flow and/or reverse rotation are normally unavailable, and
manufacturer curves are often mapped to previously published four quadrant data sets for
similar pumps. Assumptions made in this mapping process can cause extreme differences
in the simulation. If these assumptions are unaddressed, critically incorrect conclusions
about the systems transient behavior may be made, impacting both design and
operation. The available choices to the waterhammer analyst and the consequences of
those choices are thoroughly detailed in Part 1 of this paper.
NOMENCLATURE
1 INTRODUCTION
Some systems involve reverse flow through pumps during transient events. If sustained
this can lead to reverse rotation. Predicting centrifugal (rotodynamic) pump hydraulic
behavior and system response during transient events is critical to ensure safe design and
Configurations susceptible to reverse flow through pumps fall into two basic categories:
Parallel pump operation where pumps trip and at least one remains running
Pumping to a higher elevation or pressure (e.g., a rising main)
The standard method to prevent reverse flow is the use of check valves usually at the
pump discharge. Systems with check valves can have short-term, reverse pump flow
before the check valve fully closes (e.g., see Lozano, Bosch and Walters, 2018 (1)).
Some pumping systems do not or cannot use check valves, including pumping of slurries
and large condenser cooling water systems. Moreover, some pump systems are purposely
designed to have reverse flow through the pump such that the pump can run in turbine
mode and be used to generate power (Binama et al., 2017, (2)). Systems without check
valves often have power operated valves that may or may not close during a pump trip
event, depending on the design.
Predicting pump behavior under reverse flow and potentially reverse rotation is a
complicated task even with good data for a given pump. But good (or any) data is rarely
available for reverse flow or rotation. Pump manufacturers perform rigorous testing of
their pumps and publish performance data for head, power and efficiency in the zone of
normal pump operation forward flow and positive rotation. Testing is rarely performed
in the zones of reverse flow or rotation.
It was recognized as far back as the 1930s that understanding reverse flow and rotation
of pumps was going to be an important part of future engineering efforts especially in
large water works projects under consideration at the time. Important first steps in this
direction were made by Kittredge and Thoma, 1931 (3) and Knapp, 1937 (4). Progress in
the ensuing decades culminated in the publications of Marschal, Flesch and Suter, 1965
(5) and Suter, 1966 (6). What emerged from these two publications is what we know
today as the Suter Method of organizing four quadrant pump data into a dimensionless
form convenient for digital simulation.
In that it is rare to find a pump in the field operating at its BEP, this raises what should
be an obvious question. How does one properly correlate and apply four quadrant pump
data referenced to BEP to a pump operating away from its BEP? It will be shown that the
answer to this question is nowhere near as obvious and clear-cut as most seem to imply.
Further, it will be shown in Part 2 of this paper that how one answers this question can
have a dramatic effect on waterhammer simulation predictions. Finally, some guidelines
for practicing waterhammer engineers will be proposed with the goal of helping ensure
conservative predictions are obtained, thereby enhancing safety in design and operations.
While highly valuable, Swansons data was only given for lines of constant
dimensionless head and torque at 100%, 0% and -100% of rated values in the
dimensionless flow vs. speed plane. Donsky (9) obtained Swansons data (8) from A.
Hollander and, using pump similarity laws (more commonly called affinity laws in the
context of pumps), developed these into full sets of four quadrant data. Donskys curves
were still dimensionless, but converted into the more familiar (to practicing engineers)
flow vs. head plane. Further, Donskys curves were more tightly spaced at roughly 10%
increments and taken to roughly 200% of rated conditions. The Donsky curves are
familiar to every waterhammer engineer who works with pumps.
A note of caution on the Donsky curves is in order. It is well known that the affinity laws
are good approximations of predicting pump performance based on speed changes when
the flow, head and speed are all positive values. The validity of the affinity laws when
any of the head, flow and/or speed are negative is not clear to the authors.
Popular textbooks have pushed four quadrant data methodology and the
Knapp/Swanson/Donsky curves into the mainstream of waterhammer application. For
example, see Wylie and Streeter, 1993 (10), Swaffield and Boldy, 1993 (11), Thorley,
2004 (12), and Chaudhry, 2014 (13). Donsky is usually the one given credit for these
three curves and this paper, Parts 1 and 2, will follow suit and reference Donsky. All
modern textbooks present the Donsky curves in the now standard Suter Method form (5,
6) discussed in the previous section.
One of the first published four quadrant pump field studies to include friction was by
Brown, 1968 (7), a colleague of Donsky at the US Bureau of Reclamation. Browns
study also included water column separation and used Donskys four quadrant data for a
Later, Brown and Rogers, 1980 (14) published several new four quadrant pump data sets
from manufacturers and their own field studies. Despite the success using the similar
specific speed method in Browns earlier study, Brown and Rogers questioned the
validity of using pump specific speed as a correlating factor for four quadrant pump data.
The additional data they collected showed a much weaker correlation between four
quadrant characteristics and specific speed for radial flow pumps, while mixed and axial
flow pumps showed better correlation.
Recognizing the need for broad availability of pump four quadrant data sets for various
specific speeds, Martin, 1983 (15) aggregated references for 26 data sets. Thorley et al.,
1996 (16) published curves and numerical data for 14 specific speeds. Recent years have
seen additional research and aggregation of four quadrant data sets. Ayder et al., 2009
(17) published seven complete sets of data from their own experiments. Giljen et al.,
2016 (18) aggregates nine sets of partial four quadrant data.
It should be noted that some have questioned the use of steady-state, four quadrant pump
data to adequately represent transient pump behavior. This certainly goes back to Knapp,
1937 (4). Gros et al., 2011 (19) used experiments and detailed transient numerical (CFD)
methods which demonstrated such discrepancies.
To avoid calculations through the zero point, the Suter Method involves transforming the
constant head and torque lines in the speed-flow plane to a polar coordinate system via
the transformation equations below (11, 13). Note that these definitions vary depending
on the reference.
(1)
Fig. 2 shows the Suter curves as developed from the Donsky, 1961 (9) radial flow pump
data. This is the same pump as Fig. 1.
Figure 2. Suter curves constructed from a radial flow pump (4, 8, 9) via Eq. 1.
The specific speed for the test pump is Ns = 24.6 Metric (1270 US).
3.8 Summary of process for analyzing reverse flow and rotation in a system
An MC is available for a given pump but does not contain information for reverse flow
or rotation. For such a simulation, four quadrant data is required. Ideally, this data is
available for the pump in question and can be directly applied. However, four quadrant
data is rarely available. Instead, specific speed is used to select a suitably similar pump
that has been tested in all four quadrants.
The four quadrant data from the similar pump is then dimensionalized to a 4QDC with a
reference point related to the pump being studied. This reference point, derived from the
actual MC, could be very different than the one used with the original pump. With this
4QDC, an estimate for pump behavior at all flows and speeds is obtained.
The pump being analyzed will usually differ from the four quadrant test pump. Even if
the pump is running exactly at BEP, and the specific speed matches exactly, the MC and
the 4QDC will have a different shape. This is due to differences in the pump design.
What reference point should be chosen when the pump is not running at BEP? What are
the consequences of choosing certain reference points? The two most common and
straightforward choices are defined later in this section.
The real pump introduced in Fig. 3 has a specific speed almost exactly the same as the
test pump described by Fig. 1 from Swanson (8) and Knapp (4). As described previously,
Donsky (9) expanded the Swanson data and later it was organized in Suter form as
shown in Fig. 2. When the Fig. 3 pump is compared to the Fig. 2 four quadrant data
using the BEP from Fig. 3, Fig. 4 shows how the curves differ.
Figure 4. Dimensionalizing existing four quadrant data (Figs. 1-2) using the BEP
of the pump described by Fig. 3.
The fact that the 4QBEP data is representing a similar pump, rather than the pump
defined by the MC, has direct implications on the simulation. Most prominently, the
steady-state solution will not agree with the MC except by chance. This is true for
steady-state solutions anywhere on the 4QBEP, except exactly at BEP.
Fig. 5 shows the steady-state operating points determined using the MC and the 4QBEP
and the system curve. These are determined using a steady-state analysis of the system
using the MC and 4QBEP pump curves. The MC curve is the real pump curve for the
system, hence the OP determined by the MC is the real OP. The OP determined by the
4QBEP is an artifact of imperfect matching of the Figs. 1-2 data to the BEP of the MC.
Depending on how well the 4QBEP and MC happen to agree, this effect could be
significant, and is often amplified the farther away from BEP the pump is operating.
4.3 Using the steady-state operating point as the reference point the 4QOP
To overcome the issue of a mismatched initial steady-state result (between the MC and
4QBEP, as discussed in previous section), another pragmatic and convenient option is to
use the actual initial operating point (determined using the MC) as the reference point in
creating the 4QDC. This will force the initial steady-state results to match the MC
exactly. This will be called the 4QOP curve. The 4QOP uses the same data as the
4QBEP, but the reference point has been changed to the OP. See Fig. 6.
Figure 6. Dimensionalizing the existing four quadrant data (Figs. 1-2) using the
actual OP of the pump based on the same system curve shown in Fig. 5.
It should be noted that the 4QOP and MC still only exactly match at one point. Instead of
matching at BEP, they are now matched at the OP. At all other points on the 4QOP,
steady-state solutions will vary from the MC except by good fortune. This becomes
important when analyzing a final steady-state value after a waterhammer transient has
died out. Two different final operating points are predicted one for the MC (the actual
final operating point), and one for the 4QOP. See Fig. 7.
When operating far from BEP, the 4QOP method tends to cause greater distortion to the
4QDC. This can potentially cause a sense of false security the curve can be very
different than the MC, but display accurate initial steady-state results, which are the most
intuitive to check.
4.3.1 Identifying the reference point values for use in the 4QOP method
The 4QOP method requires knowledge of the initial steady-state conditions. These initial
conditions can only be determined by running a steady-state simulation with the MC.
By definition, the 4QOP and the MC intersect at the initial steady-state OP. This means
the initial conditions for the transient solution can be determined directly with the MC,
with the 4QOP only being used in the transient solution. Both curves can be used without
artificial disruption in the transient calculations.
It should be mentioned that engineers can also use the MC during the transient
simulation with a torque balance model and affinity laws. See Chaudhry, 2014 (13), pp.
125-126 for the standard torque balance, and Applied Flow Technology, 2016 (24) for
coupling torque balance with affinity laws. With MC power data vs. flow rate (always
available from a manufacture for positive flow at a given positive speed), one can easily
determine torque for a given rotational speed. This method is more accurate than four
quadrant methods in the first quadrant but cannot be used for negative flow, speed or
head. However, it can be used to check the 4QBEP and 4QOP results while still in the
first quadrant (positive flow, speed and head).
The selection of either the 4QOP or 4QBEP method can have a substantial effect on the
results of both steady-state and transient simulations. It is evident that differences in
steady-state results should be expected with either method. While the 4QOP option
forces accurate initial steady results (Fig. 6), final steady-state results after a transient
event has died out are likely to be incorrect (Fig 7). The 4QBEP is usually incorrect for
the initial steady-state (Fig. 5) as well as the final steady-state (not shown).
Transient results are more difficult to conceptualize. It is reasonable to state that, because
the operating curves are different, some transient differences may be expected. What
appear to be minor differences in the 4QDC options can, perhaps unintuitively, be the
cause of significant differences in a transient simulation.
For example, if a valve is known to close at a certain time, the 4QBEP option may
predict significant flow through the valve as it closes, causing subatmospheric pressure
conditions or even significant cavitation, whereas the 4QOP option may predict a much
lower flow through the valve, avoiding subatmospheric conditions and cavitation. One
can see how this could easily result in an engineer recommending surge suppression
equipment and devices that are not required, or, worse, not recommending surge
suppression when it is in fact needed. The authors have developed example cases
showing such effects and the differences between the 4QBEP and 4QOP options, as
presented in Part 2 of this paper. Table 1 summarizes the key differences between the
4QBEP and 4QOP. Note that MC transient torque balance method (Section 5) is always
accurate for all Table 1 conditions until flow, head or speed become negative.
7 RECOMMENDATIONS
Wan and Huang, 2011 (24) provide an alternative to the 4QBEP and 4QOP options
discussed in Section 4. What they essentially do is keep the four quadrant curve of
interest but modify it using the manufacturers curve in the first quadrant zone of normal
pump operation. This avoids the issues raised in this paper but ends up with a four
quadrant curve no longer consistent with the original test data. There also is a significant
discontinuity at zero flow in their proposed method. It is not clear to the authors whether
this offers any substantial improvement. Wan and Huang should be applauded for
recognizing that an issue exists.
For the practicing engineer, the authors have no recourse but to recommend substantial
sensitivity studies be performed in waterhammer simulations. Both 4QBEP and 4QOP
should be evaluated. Comparisons should be made to MC transient results in the first
quadrant (see Section 5). Multiple four quadrant data sets near the pump specific speed
of interest should be included. Engineers should identify the initial and final steady-
states of the system and consider transient simulation results in light of agreement with
the final steady-state results after all transients have died out.
8 CONCLUSION
9 ACKNOWLEDGMENTS
10 REFERENCES
(1) Lozano Solé, D., Bosch Segarra, R., and Walters, T. W. (2018), Surge Transients
Due To Check Valve Closure In a Municipal Water Pumping Station, Proc. 13th
International conference on pressure surges, BHR Group, Bordeaux, France, Nov
2018.
(2) Binama, M., Su, W., Li, X., Wei, X., and An, S. (2017), Investigation on pump as
turbine (PAT) technical aspects for micro hydropower schemes: A state-of-the-art
review, Renewable and Sustainable Energy Reviews, Vo. 79, Nov 2017, pp. 148-
179.