To depict the pump power characteristics of radial centrifugal pumps, a physical model was developed. The model relies on established empirical equations. To parameterize the model for specific pumps, physically interpretable tuning factors were integrated. The tuning factors are identified by using the Levenberg–Marquardt method, which was applied to the characteristic curve at a constant speed. A cross-validation of the physical model highlighted the advantage of representing the set of performance curves with less deviation compared to approximation functions. Calculating the entire set of performance curves requires only one pump characteristic curve at a constant speed. Therefore, only a single measurement is necessary. Furthermore, the physical model can be used to calculate the changes in the set of performance curves due to prewhirl. This increases the accuracy of flow rate calculations when prewhirl occurs.

Mechanical seals ensure the internal sealing of centrifugal pumps from the surrounding environment. They are one of the most critical components in a centrifugal pump. For this reason, the condition of mechanical seals should be monitored during operation. Mechanical seal friction power is an important component of mechanical losses in centrifugal pumps and is used as an indicator of wear and therefore seal condition. The soft sensor described in this paper is based on temperature measurements at the seal and can be used for determining the frictional power performance. A major factor in determining frictional power performance is the heat transfer between the mechanical seal and the medium inside the pump. For calculating the heat transfer, the stationary temperature fields in the rings of the mechanical seal are described by transmission efficiencies. The root mean squared error was determined for steady-state operating conditions to assess the quality of the soft sensor calculation. The frictional power performance can be determined by recording the temperature at the mechanical seal mating ring and the medium. The algorithm detects when the steady-state operating conditions change but does not map the dynamic changes between the stationary operating conditions.

The flow rate is a significant factor in the operation of centrifugal pumps. The characteristic curve of the pump head is frequently employed in the calculation of the flow rate. Nevertheless, this may be subject to alteration because of prewhirl on the suction side of the pump. Calculating the changes in the head’s characteristic curve reveals a change in hydraulic losses. The impact of prewhirl on hydraulic losses is investigated by experimental and numerical analysis of two radial centrifugal pumps. It is demonstrated that the primary changes occur in the pump impeller losses. Relative velocity is a significant factor in this context. Alterations in the pumps’ configurations result in a range of secondary flows and shock losses at the leading edge of the blades. A physical model, derived on the basis of the relative velocity, is used to predict the characteristic curves of radial centrifugal pumps with prewhirl with a high degree of accuracy. The results demonstrate a notable enhancement in comparison to modelling techniques that do not incorporate the fluctuating hydraulic losses.