This document discusses minimum flow systems for pumps. It describes three types of pump recycle systems used to protect pumps from operating at low flows: continuous recycle systems using an orifice, control loop systems using a control valve, and automatic recirculation systems. It provides guidance on applying each type, including considerations for sizing recycle flows, locating flow meters and control valves, dealing with pressure drops, and routing recycle lines. The document asks how pump capacity should be stated if a pump has a continuous 30 gpm recycle flow added to its 100 gpm normal flow.

1. Minimum Flow System
process-eng.blogspot.com/2012/10/minimum-flow-system.html
My friend, In this posting we will discuss about the pump recycle
systems. The pump shall be protected from minimum flow, due to
the following reasons;
1. Thermal consideration which has effect to the pump efficiency
(The efficiency will decrease significantly at low flow)
2. At low flow, Internal recirculation will be occurred
3. Increase load impeller (both axial and radial)
4. liquid containing a large amount of abrasive particles must flow continuously
through the pump. at low flow, the particles can circulate inside the pump and erode the
impeller.
The three types of pump recycle systems which are generally applied are ;
1. Continuous recycle system --> use Orifice
2. Control loop system and --> use Control Valve
3. Automatic recycle system. --> use ARC
My friend, The followings are short guidance to apply those types.
1. ORIFICE
This system will provide continuous recycle flow whenever pump is running,
regardless of the process demand.
Typically applied for pump below 50 hp (38kW), or small capacity.
Don’t forget, you must consider the additional capacity of the pump ( the
capacity is included recycle flow)
For initial estimation, 30% of rated flow can be used as recycle flow basis.
Take care for high pressure drop condition, is there any flashing? Two phase? Or
vibration? If two phases is occurred, the orifice should be located at the end of the
recycle line.
1/4

2. 2. CONTROL VALVE
When the minimum flow is reached, the valve start to open. The flowmeter shall
be located at pump discharge side (installing at suction side will decrease the
suction pressure, decrease NPSHa )
The flow meter should be located before(upstream the) recycle line connection.
Be careful with high pressure drop, control valve may be noise and vibration (an
orifice in series with the control valve may be required)p
3. AUTOMATIC RECIRCULATION
This type is the spring loaded, combined recycle and check valve
The spring loaded is set at a pressure correspond to minimum flow (based on
pump curve) where the recycle starts to open.
Check this link for the detail how the ARC valve work.
2/4

3. No need additional check valve in the discharge system. The ARC provides back
flow protection.
Take care with pump with high discharge pressure ( while low pressure source) .
The orifice may be required at the recycle line to avoid very big change of
momentum
General Guide.
Recycle line should be routed back to the source (tank or vessel) NOT to pump
suction. Bubble of two phases can be formed during pressure reduction by orifice
or control valve. It may be introduced into the pump.
Routing to suction line may causes excessive temperature build up in a very short
time.
For 2 x 100% operation, the recycle line can be connected at combined line.
For 2 x 50 % operation, each pump shall have its own recycle system.
3/4

4. -
Generally, the recycle system is not shown in the PFD. There are two specific pumps
when a recycle system should be included in the PFD. These are the BFW pump and
pump with the high head or capacity. (discharge pressure > 1000 psig)
That's all I can share this time.
Hopefully this is useful for you..
Wait ..wait..I have a question for you.
Here my simple question.
Let say, 100 gpm liquid shall be transferred via pump to a tank. The recycle is
continuous of 30 gpm use orifice.
How you state the pump capacity in the process datasheet?
A. Normal = 100 gpm , Rated = 100 +30 = 130 gpm
B. Normal = 130 gpm, Rated = 130 x 1.1 = 143 gpm
C. Normal = 100 gpm, Rated = 1.1 x 100 + 30 = 140 gpm
hhmm,,,can you explain WHY ? it is simple, isn't ? :D
Thank my friend..
4/4