NPSH made Simple for Metering Pumps

abodex.in/entries/general/npsh-made-simple-for-metering-pumps

The objective of NPSH calculations is to ensure that the Metering pump will be operating
without any cavitation risk for a given process condition. Like other PD pumps, metering
pumps selection equally affected by improper NPSH (Net Positive Suction Head). Many
people have discussed this subject very much in depth previously. The objective of this
paper is to understand very basics of NPSH effect specifically on metering pumps. Let’s
start from basic.

To avoid, cavitation in pump suction line, NPSHa > NPSHr

What is NPSH (Net Positive Suction Head)?

Pump is device which loves pumping liquid and hates pumping gas. NPSH is a
tool to decide stable positive head available in pump suction to keep pumping fluid in
liquid stage. In simple words, Net Positive suction head is the margin of pressure
over vapor pressure, at the pump suction nozzle, is Net Positive Suction Head
(NPSH).

NPSH(a) = Ps ‑ Pvap

Where:

NPSH = NPSH available from the system, at the pump inlet, with the pump running
Ps = Stagnation suction pressure at the pump inlet when pump is in operation.
Pvap = Vapor pressure of the liquid at pumping (operating) temperature

VAPOUR PRESSURE

Since vapor pressure is always expressed on the absolute scale, suction

pressure must also be in absolute terms. In Metric unit system, Head or Pressure is
calculated as Kg/cm2 (a) or Bar (a) or MWC (i.e. meter of water column), mmHgC (i.e.
mm of Hg column)

Absolute pressure = Gauge pressure + Atmospheric pressure

Let us talk little bit in depth about vapor pressure.

The vapor pressure of a fluid is the pressure, at a given temperature, at which a fluid will
change to a vapor. Each fluid has its own vapor pressure/temperature relationship. Vapor
pressure curve for water is as below

1/7
To illustrate this point, let’s look at water. At 0oC, the vapor pressure of water is 0.0059
Bar(a). This means that for water at 0oC, if the external pressure drops below 0.0059
Bar(a) (pretty serious vacuum), the water will flash off and boil. At 20oC (more or less
ambient water temperature), the vapor pressure of water is 0.023 Bar(a) (still a pretty
strong vacuum). At 100 oC, the vapor pressure of water is 1.0135 Bar (a) or
atmospheric pressure.

In case pump is pumping water at 100oC, having vapor pressure 1.0135

Bar(a). If the pump pressure at the inlet of the pump drops below the
atmospheric pressure (1.0134 Bar (a)), the water will flash off and convert
into vapor phase. This will wreak havoc on your system, causing cavitation,
pump life deterioration, and other inefficiencies.

Hence it is necessary to know vapor pressure of liquid being pump at inlet or pumping
temperature and we need to ensure that Suction head is higher than vapour
pressure of liquid at pumping temperature which ensure to keep liquid in
liquid phase only at pumping temperature.

Apart than vapor pressure, we need to take care of effect of Viscosity and Specific Gravity
of liquid being pumped.

VISCOSITY:

Metering pump performance is not affected by liquid viscosity upto 1000 cp with flat
diaphragm construction. However, in case product viscosity is more than 1000 cp, suction
line friction losses will increase, and it plays vital role in NPSH Calculation. It is advisable
to pay attention to proper pipeline sizing; Liquids are pumped at low velocities
from 0.5 to 2 m/s because they yield the best compromise between pipe
friction losses (running costs) and capital costs (pumps and pipework cost).

2/7
Liquid velocity across the check valve shall be maintain in same range by maintaining
pump speed as well. Prefer Pump speed in range of 25 to 50 SPM for high
viscous liquid pumping. (Please consult pump manufacturer for proper pump
selection).

You may use piping friction calculation using online software which is accurate

http://www.freecalc.com/fricfram.htm

SPECFIC GRAVITY

The term specific gravity compares the density of some substance to the density of water.
Since specific gravity is the ratio of those densities, the units of measure cancel
themselves, and we end up with a dimensionless number that is the same for all systems
of measure. Therefore, the specific gravity of water is 1— regardless of the measurement
system. Specific gravity is important when calculating static head.

STATIC HEAD: Head resulting from elevation of the liquid relative to the pump
center line. If the liquid level is above pump center line, Head (H) is positive. It is
known as flooded condition.

If the liquid level is below pump center line, Head is negative. Negative (H) condition is
denoted as a “suction lift” condition

Total Static Head = [ (+/-) H ] / [( S.G.)]

Static head is greatly influence by Specific Gravity.

Where, H : Static Head & S.G.: specific gravity.

ACCELERATION HEAD LOSS: (PAHL)

This is a new terminology which is used mainly for positive displacement reciprocating
pumps. In case of reciprocating pump, liquid is always pumped into head during reverse
stroke while there no pumping takes place during forward stroke. It means that flow

3/7
velocity of liquid getting into pump head is disturbed during every cycle of pump stoke.

During every reverse stroke, fluid velocity reaches to its peak and every forward stroke
this velocity drops down to zero. Hence there is an energy required to change the velocity
of liquid in the system from an at rest or zero condition to some non-zero value. (or peak
value) which is known as Acceleration head. This is acceleration head component of
NPSHA for reciprocating pumps and can be calculated using below formula:

PAHL= [ L.Vn.C] / [K.g] ]

Where,

L = Actual suction pipe length in feet

V = Mean flow velocity in suction line in feet / sec
n = Pump speed in cycles per minute
C = Constant (Depends on pump type)
K = A factor representing the reciprocal of the fraction of the theoretical
acceleration head which must be provided to avoid a noticeable disturbance in the
suction line
g = Gravitational constant (32.174 ft/sec2)

V= 0.0485 * Q/ D2

Where:

V = Mean flow velocity in suction line in feet/sec

Q = Flow rate in gallons per minute
D = Pipeline inside diameter

Constant `C’ Pump Type

0.200 Duplex single-acting (diaphragm pump)

0.115 Duplex double acting

0.066 Triplex (single or double acting)

0.040 Quintuplex (single or double acting)

0.028 Septuplex (single or double acting)

0.022 Nonuplex (single or double acting)

Factor `K’ Liquid

4/7
 2.5 Hot Oil

2.0 Most Hydrocarbons

1.5 Amine, glycol, water

1.4 De-aerated water

1.0 Urea and liquids with small amount of entrained gases

Now let’s calculate the NET POSTIVE SUCTION HEAD FOR SUCTION PIPING.

NPSH(a) = Ps ± H – Pf – Pv – PAHL

Where,

NPSH(a): Net positive Suction Head available.

Ps : Stagnation Suction Pressure , (MWC) (Atmospheric Pressure for open
system) or System Pressure in case of closed system)
H: Static Head, (MWC)
Pf : Piping Frictional Losses, (MWC)
Pv: Vapor Pressure of liquid at pumping temperature, (MWC)
PAHL: Acceleration Head Loss, (MWC)

Based on above given expression, one can find out NPSHa.

NPSH(R) – NET POSITIVE SUCTION HEAD REQUIRED.

Now we need to understand the term NPSH(R). It is a minimum pressure or head or

energy required for liquid within the pump to overcome the friction losses from suction
nozzle to discharge nozzle without causing any vaporization (cavitation). The NPSH(R) is
a function of the pump and must be provided by the pump manufacturer. The NPSH(R)
is unique to each pump depending on the pump design, pump size, RPM and operating
conditions. Generally Metering pump are designed with NPSH(R) reasonably
between 2 to 3 MWC or 3 to 5 PSI.

For Healthy suction side pumping application, NSPH(A) shall be greater than
NPSH (R)

then pump is comfortable to receive feed at mount of suction port and pump
will work in smooth condition up to lowest liquid level in source tank.

HOW TO IMPROVE NPSH MARGIN?

5/7
The main challenge lies in case NPSH(A) is lower than NPSH(R). Minimum margin shall
be 1 MWC to ensure reliable pump operation at lowest liquid level. Even though the
options to increase the NPSH Margin to a pump are generally limited in an existing
installation, there are still some choices available. Points are spelled out below,

1. Increase the liquid level in the suction vessel to increase static head.
2. Avoid suction lift condition.
3. Eliminate any flow restrictions in the suction piping (such as a strainer). It is
recommended to use Full bore isolation valves in suction line.
4. Installed pump very close to source tank to reduce piping friction losses.
5. In case liquid vapour pressure is higher at pumping temperature, it is insisted to
have source tank with inert gas Blanketing
6. Reduce Acceleration Head Loss by adopting below listed possible options.

1. Reduce Acceleration Head Loss

5. Increase pipeline diameter to reduce friction loss and liquid velocity

5. Move the pump as close as possible to the source of the supply to reduce the mass
that must be reaccelerated on every stroke and to reduce friction loss
5. Straight pipe for at least 10-15 pipe diameters at the pump inlet to minimize
turbulence
5. Use multiplex Pumping Head with common suction header to reduce acceleration
head loss which may turn into expensive choice hence use this preference carefully.

2. Reduce Acceleration Head Loss using Volume Bottle suction

Accumulator.

Suction Volume Bottles type accumulator is recommended to use only

Metering pump capacity is < 100 GPH or < 400 LPH.

Air contamination to process liquid is acceptable.
For Atmospheric source or low suction pressure feed to pump

Suction volume bottle type accumulator can be designed to reduce AHL upto 95%. It is a
simple vertical cylindrical shell with top and bottom end caps. Bottom cap shall have
inlet/outlet (common nozzle) and top end shall be provided with coupling with plug. This
volume bottle accumulator needs to be installed within 10 Diameter distance (or as close
to pump inlet nozzle as possible) on pump suction line. Volume Bottle provide an area of
accumulation and release of pumped liquid as the pump’s inlet valve alternatively opens
and closes and feed to suction will be made available.

3. Reduce Acceleration Head Loss using Inlet Bladder type suction

Stabilizer.

Bladder type Inlet stabilizer is recommended for all type of application. An inlet stabilizer
has a flexible internal diaphragm or bladder to prevent mixing of the system liquid with
the stabilizer’s gas charge. Properly sized and installed in a tee 10 pipe diameter of the
pump inlet, it can usually reduce acceleration head loss to less than 3 to 4 psi. It does this

6/7
by accumulating liquid during the pump’s discharge stroke and releasing the liquid back
into the suction line during the pump’s inlet stroke. In effect, the inlet stabilizer uses the
stored energy of the compressed gas to reaccelerate the liquid back into the suction line. It
will only have an effect on the liquid between it and the pump inlet so proper location is
critical.

CONCLUSION :

In conclusion, it is important to consider several factors related to inlet piping for positive
displacement pumps, specifically reciprocating pumps. Acceleration head loss is very
important element when calculating NPSHA. Since acceleration head loss depends on
both system parameters (pipe diameter, length, liquid details etc) and pump sizing (stroke
rate, pump type- single acting or double acting, no of heads), acceleration head loss
calculations are often overlooked and misunderstood. With suitable system design at the
pump inlet, which may include standpipe or inlet stabilizer, improved pump performance
will be obtained by reducing acceleration head loss.

You can contact us +919821891092 or info@abodex.in for any questions.

7/7