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#4: pump heat becomes a significant factor. You would do well by being able to calculate the induced heat. Note that the pump heat appears at the flow restrictions, and not within the pump.
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I disagree. I've hooked a meter up to a 25w Eheim 1250 and found that it used 7-8w running in my system. Plus the casing was a bit warm even through it was mounted with a case fan blowing cooled intake air over it.
Pumps are rated like TVs, power supplies, or fridges. They have an actual ussage and then a max ussage two or three times as high to cover the manufactor's ass. Like my 300w power supply that says it uses 7amps at 120v
My guess is you'd need to be at 50+ w (rated, not actual) before pump heat started to be at all relevent. Even a 100w would probably be unnoticed to anyone but Bill . . . Of course a tiny rad is another issue, but most of us run heatercores anyway.