CHAPTER 7

CAPACITY REGULATION
While fluid machines should run around their design capacity, in most applications the
capacity required by the system will not be the same as the design capacity of the
machines. In addition for various reasons the capacity required by the system may change
from time to time. Therefore regulating the capacity of fluid machines is an essential
issue. The various techniques used for regulating the capacity of fluid machines are
discussed in this chapter.

7.1 DYNAMIC PUMPS

Capacity regulation methods for systems using centrifugal and axial flow pumps and fans
are similar. The main methods are regulation by throttling, speed, bypass regulation and
multiple pumps in parallel and series. Each of these regulation methods are discussed in
the following section.

7.1.1 Regulation by Throttling

Regulation by throttling is the simplest and cheapest capacity regulation method. The
capacity is varied by varying the flow area of a valve placed at the discharge or suction
line.

Figure 7.1 shows how capacity regulation is achieved through throttling. When the flow
area of the valve is reduced the resistance for flow increases and the system dynamic
head increases. The working point also changes accordingly. When the required capacity
is reached the throttling process is stopped.

187
Chapter 7 Capacity Regulation 188

Working point
after throttling Effect of
throttling

H[m] Pump characteristic

curve
Working point
before throttling
System characteristic
curves

Q[m3/hr]
Figure 7.1 Capacity regulation by throttling

Discharge throttling
This is the simples, cheapest and most common method of capacity regulation for
systems using centrifugal pumps. A throttling valve is placed in discharge line and by
adjusting the opening of the valve the required capacity is achieved.

Regulation valve in
discharge line

Figure 7.2 Discharge throttling

Suction throttling is similar to discharge throttling except the fact that the valve is
placed in the suction line. Suction throttling is not advisable for pumps, since pressure
drop across capacity regulation valves is significant and can reduce the NPSHA making
the system susceptible for cavitation.

Regulation valve in
suction throttling

Figure 7.3 Suction throttling (Not advisable for pump- systems)

Chapter 7 Capacity Regulation 189

Capacity regulation can be easily shown using the characteristic curves of the pump and
the system. By similar analysis it can be shown that no appreciable capacity regulation is
achieved by throttling in systems with positive displacement pumps. The reader is
encouraged to check this.

7.1.2 Regulation by Speed

When the pump is driven by steam turbine or variable speed pump capacity regulation by
speed is a good method. Figure 7.4 shows how capacity regulation is achieved by speed.
The characteristic curve at a different speed can obtained by applying the affinity laws for
discrete points and joining them by a smooth curve.

Pump characteristic
curve at speed N2
N2>N1

H[m]
Pump characteristic
curve at Speed N1

System characteristic
curve

Q[m3/hr] Q1 Q2
Figure 7.4 Capacity regulation by speed

-
7.1.3 Bypass Regulation ( for pumps)
Running pumps at flow rates far below the design flow rate is not advisable. Besides
inefficiency it can also damage the pump since the flow medium serves as lubricant in
pumps most of the time and decrease in flow rate may result in inefficient lubrication and
cooling in cases when rotary elements come in contact with stationary parts. Bypass
regulation is a good alternative in such cases. Bypass regulation is in essence running the
pump at a higher flow rate and returning the rest to the source. Figure 7.5 shows a system
regulated using bypass method.
Chapter 7 Capacity Regulation 190

Bypass line

Figure 7.5 Bypass regulation

7.1.4 Pumps in Parallel and in Series

When there is significant variation in system head and flow rate requirements multiple
pumps can be used in parallel or in series to get the desired flow rate or head.
Pumps in parallel
Multiple pumps in parallel are used when it is desired to get higher flow rate. Figure 7.6
shows pumps arranged in parallel.

Pumps in series

Figure 7.6 Suction throttling (Not advisable for pump- systems)

The operating point of each pump can be obtained by drawing the overall characteristic
of the pumps in the system and the system characteristic. It should be noted that when
pumps (fans) work in parallel the head against which they are working will be the same
and total flow rate will be the sum of the flow rate of the pump at the working head. The
overall characteristic curve of the two pumps (or fans) working in parallel is obtained by
adding the flow rates for the same head. The procedure for drawing the overall
characteristic curve is as follows:
From the characteristics of the two pumps select heads common to both
pumps
Find the corresponding flow rate of each pump for those common heads
Chapter 7 Capacity Regulation 191

The total flow rate of the two pumps working in parallel for each common
head is the sum of the flow rate of each pump at that head
Draw the characteristic curves as shown in Figure 7.7

Characteristic curve Characteristic curve Characteristic curve

of pump 1 of pump 2 of pump 1+2 in
parallel

H[m]

Q1 Q[m3/hr] Q2 Q1+ Q2
Figure 7.7 Capacity regulation using two pumps working in parallel

Pumps in series
Series arrangement is used when it is desired to get increased head. When pumps are
working in series their volume flow rate is the same and their respective head is obtained
from their characteristic curve if the common flow rate is obtained.

Pumps in series

Figure 7.8 Suction throttling (Not advisable for pump- systems)

Their common flow rate is obtained by finding the intersection point of the overall
characteristic curve of the pumps working in series with the system characteristic curve.
The procedure for drawing the overall characteristic curve is as follows:
From the characteristics of the two pumps select flow rates common to
both pumps
Chapter 7 Capacity Regulation 192

Find the corresponding heads of each pump for those common flow rates
The total head of the two pumps working in parallel for each common
flow rate is the sum of the flow rate of each pump at that flow rate
Draw the characteristic curves

Example 7.1
The performance characteristic of two pumps is given in Table 7.1. The characteristic of
the system at which they are used is given in Table 7.2. Determine the capacity
i) The flow rate if the two pumps work in series
ii) The flow rate if pump1 works alone
iii) The flow rate if pump 2 works alone
iv) The flow rate if the two pumps work in parallel
Table 7.1 Performance characteristics of Pump1 and Pump 2
Q(m3/hr) common 0 50 110 180 220 270 300
H1(m) Head of pump 1 50 49 46 40 34 25 16
H2 (m)Head of pump 2 52 51 49 45 41 32 22

Table 7.2 System characteristics

Q(m3/hr) common 0 50 110 180 220 270 300
Hsystem(m) 60 60.6 62.7 67.1 70.6 76.0 79.8

Solution
i) The overall performance characteristics if the two pumps work in series is found
by adding the heads for common low rates. Table 7.3 summarizes the values.

Table 7.3: The overall performance characteristics for the two pumps in series
Q(m3/hr) common 0 50 110 180 220 270 300
H1(m) Head of pump 1 50 49 46 40 34 25 16
H2 (m)Head of pump 2 52 51 49 45 41 32 22
H1+H2 102 100 95 85 75 57 38
Chapter 7 Capacity Regulation 193

The characteristic curves become as shown in Figure 7.9. Reading the graph at the
working point, the flow rate is obtained to be 230 m3/hr.
Characteristic curve of
120 the two pumps
working in series
Working point of
100 the overall system

H [m] 80

60

40

20

0
0 50 100 150 200 250 300 350
3
Q [m /hr]
Figure 7.9 Characteristic curves of two pumps working in series

ii) Since the system characteristic curve doesnt have intersection point with
pumps characteristics pump 1 doesnt deliver any liquid if it works alone. The
energy requirement is larger than the energy that the pump can deliver.
iii) The same as (ii)
iv) If the pumps work together in parallel there will not be increase in head. The
system characteristics still will be above the pumps overall characteristics.
Therefore no liquid will be delivered in this case also.

Overall Efficiency of Pumps Working in Parallel

For two pumps
gH (Q1 Q2 )
(7.1)
N b,1 N b, 2

gHQ1 gHQ2

N b,1 N b, 2 N b,1 N b, 2

gHQ1 / N b,1 gHQ2 / N b, 2

1 N b, 2 / N b,1 1 N b,1 / N b, 2
Chapter 7 Capacity Regulation 194

With
r N b, 2 / N b,1

and since 1 gHQ1 / N b,1 and1 gHQ2 / N b, 2

1 2

1 r 1 1/ r
1 r 2
(7.2)
1 r
Overall Efficiency of Pumps Working in Series
Similar analysis leads us to the result
1 r 2

1 r
Therefore the formula is the same when the pumps work in parallel and series.
When the pumps have equal brake power
r=1
1 1.2 1 2
(7.3)
11 2
Therefore if the pumps have equal brake power the overall efficiency will be the
arithmetic mean of the efficiency of the pumps.

Example 7.2
The efficiencies of two pumps P1 and P2 working in parallel are 0.76 and 0.68
respectively. The brake power of P1 is 3.5 kW and P2 is 4.2 kW. Determine the overall
efficiency of the pumps when they work together in parallel or series.

Solution
1=0.76
2=0.68
0.76 (4.2 / 3.5)0.68
0.716 71.6%
1 (4.2 / 3.5)
Therefore the overall efficiency of the two pumps working together in parallel or
series is 71.6%
Chapter 7 Capacity Regulation 195

7.2 FANS
The capacity of fans can be regulated by speed, multiple pumps in series and parallel,
throttling with a damper, and inlet guide vanes. The principles used in the first three types
of regulations are the same as centrifugal pumps. The remaining two are discussed below.

7.2.1 Adjustable Outlet Dampers

A shuttle like mechanism mounted on the fan outlet changes the Pressure- Capacity
characteristics of the fan as shown in Figure 7.10 below. This method, though relatively
inefficient, is simple in construction and is the lowest in first cost. Therefore it is the most
commonly used capacity regulation method for small duties where the power cost is not a
decisive factor. In medium and large duty tasks it is used in competition with the other
methods.

Dampers in open
position System Characteristics
H(m)
Dampers
closing

Q(m3/hr)
Figure 7.10 Effect of dampers on fan characteristics

7.2.2 Inlet Guide Vanes

Inlet-guide vanes are adjustable vanes at the inlet of fans. They change the inlet angle of
the incoming gas relative to the rotating impeller. This changes the flow characteristic in
response to varying load requirements. Inlet guide vanes can be used both to increase the
head and to reduce it by causing change in the characteristic curve.

7.3 POSITIVE DISPLACEMENT PUMPS

Due to the difference in the performance characteristics of positive displacement pumps
and turbo-pumps the capacity regulation methods are also different. As it is shown in
Figure 7.11, no appreciable capacity regulation is achieved by throttling.
Chapter 7 Capacity Regulation 196

Working point Pump characteristic

After throttling curve (nearly vertical)

H[m]

Working point
Before throttling

System characteristic
curves

Q[m3/hr]
Figure 7.11 No appreciable capacity regulation is achieved by throttling
for systems with positive displacement pumps.

The capacity regulation methods commonly used for positive displacement pumps are:
Regulation by speed, bypass regulation and regulation by stroke length adjustment (for
reciprocating pumps).

7.3.1 Regulation by Speed

The capacity of positive displacement pumps is seen to be proportional with the speed
and the characteristic curve is nearly vertical. Therefore by changing the speed of the
drive the capacity of the pump can be varied effectively. Figure 7.12 shows how capacity
regulation is achieved by changing the speed of the rotor.

Pump characteristic Pump characteristic

curve at speed n1 curve at speed n2 > n1

H[m] Working point

At speed n1
Working point
At speed n2

System characteristic
curves

Q[m3/hr]
Figure 7.12 Capacity regulation by speed for PD pumps.
Chapter 7 Capacity Regulation 197

7.3.2 Bypass Regulation

The bypass regulation used for positive displacement pumps in essence is the same as
that discussed for centrifugal pumps: return the excess fluid to the source. It should be
noted that in bypass regulation the required flow rate can be adjusted by manipulating the
valve in the discharge line. Increasing the resistance of the discharge valve will cause
more liquid to flow in the bypass line. If the discharge line is closed, all the liquid will
circulate in the bypass line.

7.3.3 Regulation Stroke Length (Piston Pumps)

It was shown in chapter 5 that the capacity of reciprocating pumps is proportional to the
stroke length also. The equation for single acting, single cylinder reciprocating pump is
given below. It can be seen that by using adjustable stroke length it is possible to vary
and hence regulate the capacity .The effect is similar to that shown in Figure 7.12.

Q D Sn vol
2
(5.1)
4

7.4 DYNAMIC COMPRESSORS

Capacity regulation by speed is one of the mostly used methods in centrifugal
compressors. When constant speed drive (electric motors, gas turbines) is used inlet guide
vanes adjustment, suction throttling or discharge throttling should be used. The flowing
part discusses these methods of capacity regulation in dynamic compressors.

7.4.1 Speed Regulation

Centrifugal compressors and blowers performance follow the affinity laws, regarding
the variation of head, flow rate and brake power. Hence, the capacity of centrifugal
compressors, like that of pumps and fans can be regulated by changing the speed of the
drive. Wide range of speed variation is possible when the compressor is driven by steam
turbine or internal combustion engine.
Chapter 7 Capacity Regulation 198

7.4.2 Inlet Guide Vanes

Inlet-guide vanes are adjustable vanes at the inlet to the first stage and sometimes to
succeeding stages that cause the angle of approach of the incoming gas to change relative
to the rotating impeller. This changes the flow characteristic in response to varying load
requirements.

Surge line with

open vanes

Head capacity curve

Had (m) for completely open
vanes

Head capacity curve for

various van positions

Q (m3/hr)
Figure 7.12 Effect of guide vanes on performance characteristics of
centrifugal compressors

Capacity regulation by guide vanes is very efficient procedure but the vanes are
expensive and need auxiliary parts for adjustment. Proper cost analysis should be carried
out before selecting this technique.

7.4.3 Suction Throttling

When the suction flow is throttled the pressure of the gas at the inlet of the impeller
reduces due to the pressure drop across the valve. This action results in a higher total
head if the discharge pressure is kept constant and the dynamic head of the system is
changed. Therefore just as in the case of centrifugal pumps (Figure 7.1) the working point
is changed and the required flow can be obtained.

7.4.4 Discharge Throttling

At reduced flow the compressor develops more head than the process requires. This extra
head is removed by throttling before passing to the process equipment, but the energy
consumed is wasted. Therefore this method is relatively inefficient. However, the fact
Chapter 7 Capacity Regulation 199

that it is simple makes it applicable for small duty compressors where efficiency is not a
critical issue.

7.5 RECIPROCATING COMPRESSORS

The inlet volume flow rate of a reciprocating compressor, developed in chapter 6, is
given by Equation 6.8. The capacity regulation methods are clearly understood using this
capacity equation and the indicator diagram.

Qi Vdis (1 a( 1 / n 1))lk th n (6.8)

Some of the most commonly used capacity regulation methods for systems using
reciprocating compressors are speed regulation, opening the inlet valve, clearance
variation and bypass regulation.

7.5.1 Regulation by Speed

As it can be seen in Equation 6.8 the capacity of reciprocating compressors depends
directly on the speed. Therefore whenever a variable speed drive like steam turbine or IC
engine is used capacity regulation by speed is a good option. However, small
compressors are commonly driven by electric motors and variable speed motors for such
uses are mostly unjustifiable. Hence other types of capacity regulation are commonly
used.

7.5.2 Opening Inlet valves

Opening inlet valves also called reverse flow control uses an unloader to hold the suction
valve open during a portion of the discharge stroke. The delayed closing of the suction
valve causes the gas in the compression chamber to be pushed back to the suction line as
long as the suction valve is open. As soon as the suction valves are closed the remaining
gas in the compression chamber is compressed and discharged.
Chapter 7 Capacity Regulation 200

7.5.3 Varying Clearance Volume

It is well discussed in chapter 6 that the expansion of the left over gas in the clearance
volume of reciprocating compressor significantly affects the capacity. Therefore by
varying the clearance volume it is possible to achieve capacity regulation. There are two
ways of varying the clearance volume:

Attaching fixed clearance volume to the compressor cylinder by a means of

some shutoff mechanism. The fixed clearance volumes can be attached to the
valve port. Compressor capacity can be varied in steps only by opening and
closing the valve to the attached clearance volume.

Attaching variable clearance volume to the head of the cylinder. This consists
of a volume of bottle with a movable piston and normally a manually operated
spindle to move the piston. Leakage is a problem in variable clearance volume.

7.5.4 Bypass Regulation

The basic principle of bypass regulation is already discussed. This method is the worst
choice in most of the cases. There two reasons for this are: (i) the energy used to
compress the excess gas is wasted (ii) the gas from the discharge line is hot and it should
be cooled to the suction temperature before it is turned back to the suction line. This
method is used only when the other cases are too difficult or impossible for certain
reason.

7.6 ROTARY COMPRESSORS

Just as in the other positive displacement machines the common capacity regulation
method is speed regulation. In compressors driven by steam turbine and variable speed
motors, this is most acceptable method of regulation. Bypass regulation is also used,
even though it is the most energy inefficient method. Its simplicity in construction and
control are the driving forces for using bypass control. Some screw compressors have
slides that change the inlet port timing and allow the capacity to be adjusted to any value
between the full capacity and some minimum capacity.
Chapter 7 Capacity Regulation 201

REVIEW EXERCISE
1. Why is discharge throttling more appropriate than suction throttling in pumping
systems using centrifugal pumps?

2. Explain why in system using pumps with steep characteristic curves bypass
regulation is more advantageous than discharge throttling.

3. By pass regulation is not the preferred method of regulation for compressors

explain the reason?

4. Explain how capacity regulation by speed is achieved in centrifugal and

reciprocating pumps.

5. In what situation should parallel arrangement or series arrangement be considered

as an appropriate capacity regulation method?

6. How is capacity regulation in piston compressors achieved by varying the

clearance volume of the compressor?

7. Which drives are appropriate when capacity regulation by speed in a wider range
is intended?

8. The efficiencies of two pumps P1 and P2 working in parallel are 62% and 68.3%
respectively. The brake power of P1 is 20.5 kW and P2 is 18 kW. Determine the
overall efficiency of the pumps when they work together.

9. Two fans having the nearly equal brake power have efficiencies of 78% and 82%
determine the overall efficiency when the two fans work in parallel and in series.
Chapter 7 Capacity Regulation 202

10. A centrifugal fan running at a speed of 1500 rpm is used to move air at 250C and
1 atm (101.325 kPa) through a duct. The head capacity curve and efficiency curve
of the fan and the characteristic curve of the system are given in Figure E1. If the
speed is increased to 2000 rpm and made to work at the best efficiency point what
will be the flow rate, head and coupling power.

40 0.8

35 0.7

30 0.6

25 0.5

Efficiency
H[m]

20 0.4

15 0.3

10 0.2

5 0.1

0 0
0 50 100 150 200 250 300 350 400
Q [m3/hr]

Figure E7.1: Performance characteristic of a centrifugal pump

REFERENCES
[7.1] Matley,J., Fluid Movers: Pumps, Compressors, Fans and Blowers,
1979,McGraw-Hill
[7.2] Karassik, I.J., Krutzsch,W.C., (etal ), Pump Handbook, 2nd Edition, 1986,
McGraw-Hill.
[7.3] Karassik, I.J., McGuire, T., Centrifugal Pumps, Chapman &Hall, 1998
[7.4] Cherkassky: Pumps, Fans and Compressors, Mir Publisher,1977.
[7.5] Hanlon, P.C., Compressor Handbook, McGraw-Hill, 2001
[7.6] Bleier,F.P., Fan Handbook, McGraw-Hill,1998