PUMP (SELECTION)

PUMP (PROCESS DESIGN)

Pipe type Economic pipe diameter, d Pipe length, l Pipe cross sectional area, A Fluid type Pump in charge Viscosity, Density, Mass flow rate, m Gravitational acceleration, g Commercial steel pipe 50 mm 7.64 m 1.9635E-03 m Fluid from M-102 P-102 0.740 mNs/m 977.652 kg/m 5489.516 kg/h 9.81 m/s
Carbon steel or Stainless steel? Estimated pipe internal diameter: Get the economic pipe diameter from DN table in Appendix referring to M-102 the Fluid from50 estimated pipe internal diameter.

Stainless steel 25 mm

Other types: d = (4A/) A=V/u V=(m/3600)/ u = 2 m/s (typical) Carbon steel: d, optimum = 293G0.53-0.37 Stainless steel: d, optimum = 260G0.52-0.37

32.174 ft/s

(1) Select pipe type with respect to fluid type

(2) Select pipe material (3) Estimate pipe internal diameter (4) Choose economic pipe diameter (5) Determine pipe length

PUMP (PROCESS DESIGN)

(6) Determine fitting/valve
Pressure loss in pipe fittings and valves (for turbulent flow, Re > 4000)

K , number of velocity Fitting/Valve 45 standard elbow 45 long radius elbow 90 standard radius elbow 90 standard long elbow 90 square elbow Tee-entry from leg Tee-entry into leg Union and coupling Sharp reduction (tank outlet) Sudden expansion (tank inlet) fully open open Gate valve open open fully open Globe valve, bevel seat open Plug valve open

Number of equivalent pipe diameters per heads per unit unit 0.35 Range: 0.6 - 0.8 15 0.2 10 0.8 35 0.45 23 1.5 75 1.2 Range: 30 - 40 60 1.8 90 0.04 2 0.5 25 1.0 50 0.15 7.5 16 800 4 200 1 40 6 300 8.5 450 0.4 18

Unit I O

K , number of velocity heads 0 0 1.6 0 0 0 0 0 0.5 1 0 0 0 0 0 0 0.4 3.5

1 1

1 Total:

Number of equivalent pipe diameters 0 0 35 0 0 0 0 0 0 50 0 0 0 0 0 0 0 85

(7) Calculate number of equivalent pipe diameter

PUMP (PROCESS DESIGN)

(8) Check Reynold number (laminar or turbulent?) z 3.90 m
PIPING LAYOUT
2

z1

1.00 m

(9) Calculate total developed head P

Static Head

P1
2

1.013 bara 1.013 bara

1.013E+05 N/m 1.013E+05 N/m

Total Developed Head (TDH)

Difference in elevation, z = Difference in pressure, P = as head of liquid = Total static head = Fluid velocity, u = Pipe cross sectional area, A = Volumetric flow rate, v = 2.90 0 0.000 2.900 0.794 1.963E-03 5.615 0.001560 52445 0.046 0.000920 0.007029 11.89 4125 41.39 44.29 m N/m m m m/s m m/h m/s mm

Take 2 m/s, typical velocity for liquid. A = /4 (d 0.001m/1mm) v = u A 3600s/1h Re = ( u d) / Refer to data in Appendix Relative roughness, e = absolute roughness/d f = 0.04Re-0.16 for turbulent flow in clean commercial (Genereaux, 1937) steel pipes. (Genereaux, 1937) Otherwise, refer to Fig. 5.7. (Satisfactory: Flow is turbulent) L = l + (total equivalent pipe diameters d0.001m/1mm) Pf = 8f(L/d) ( u)/2 (OK) Pressure drop as head of liquid = Pf / ( g) m N/m TDV = total static head + dynamic head m m (Use: Single- or double-suction pump) m Single-suction centrifugal pumps handle up to 0.0032 m/s at m/h total heads up to 15 m; either single- or double-suction % pumps used for the flow rates to 0.063 m/s and total heads to 91 m; beyond these capacities and heads double-suction or (Chopey, 2004) multistage pumps are used. (Chopey, 2004)

Dynamic Head

Reynolds number, Re = Pipe absolute roughness = Pipe relative roughness, e = Friction factor, f = Length including misc. losses, L = Pressure drop, Pf = Dynamic head = Total Developed Head (TDH) = Operating point = Refer to Operating volumetric flow, vo = Manufacturers Pump Pump efficiency = Curve

(10) Determine pump suction type

PUMP (PROCESS DESIGN)

Net Positive Suction Head (NPSH)
Total length to pump inlet, Li = Total length of inlet piping, LT = Vertical distance to pump inlet, H = Vapor pressure of liquid at the pump suction, Pv = Operating fluid velocity, uo = Reynolds number, Re = Friction factor, f = Pressure drop, Pf = NPSH = 3.44 m 5.19 m 0.50 m 71300 0.794 52445 0.007029 1800 3.44 4.20 m 8.45 m (Total length from pump outlet) (Total length of outlet piping)

N/m m/s Re = ( uo d) /

L = l + (total equivalent pipe diameter for miscellaneous friction loss due to tanker outlet constriction and the pipe fittings in the inlet piping d0.001m/1mm) As a general guide, NPSH should be above 3 m for pump capacities up to 100 m/h, and 6 m above this capacity.

Pf = 8f(LT/d) ( uo)/2 NPSH = P1/g + H - Pf/g - Pv/g

N/m m

(Satisfactory: No Cavitation)

(11) Calculate NPSH

(12) Check: Cavitation possible?

PUMP (PROCESS DESIGN)

Pump and Line Calculation Sheet
Job no. Sheet no. P-102 1 Fluid Temperature Density Viscosity Normal flow Design max. flow 20% SUCTION CALCULATION Line size u1 f1 L1 f1L1 u1/2 Flow Velocity Friction loss Line length Line loss Entrance (1) Sub-total z1 gz1 Equip. press (2) Sub-total (3) Suction press (4) VAP. PRESS. (5) NPSH Static head Norm. 2.90 0.12 3.44 0.42 4.11 4.53 0.00 50 mm Max. Units 0.00 m/s 0.00 kPa/m 3.44 m 0.00 kPa 0.00 kPa - kPa 0.00 kPa 0.00 m z2 gz2 Equip. press (max) Contigency Static head 1.00 1.00 m 9.59 9.59 kPa 101.30 101.30 kPa None None kPa By LWS 2/4/08 Checked Fluid from M-102 24.84 977.652 0.740 Units DISCHARGE CALCULATION C Line size 50 kg/m Flow Norm. Max. mNs/m u2 Velocity 2.90 0.00 f2 1.525 kg/s Friction loss 0.12 0.00 L2 1.830 kg/s Line length 4.20 4.20 f2L2 Line loss Orifice 30% Control valve Equipment (a) Heat ex. (b) (c) (6) Dynamic loss 0.51 0.51

mm Units m/s kPa/m m

0.00 kPa - kPa - kPa - kPa - kPa - kPa 0.00 kPa

(40 kPa) Strainer

(2) - (1) (3) - (4) (5)/g

0.00 0.00 kPa 101.30 101.30 kPa 101.3 101.3 kPa 96.773 101.3 kPa 0.00 0.00 kPa 96.77 101.30 kPa 10.09 10.56 m

(7) Sub-total 110.89 110.89 kPa (7) + (6) Discharge press. 111.40 110.89 kPa (3) Suction press. 96.773 101.3 kPa 14.63 9.59 kPa (8) Diff. press. (8)/g 1.53 1.00 m Control valve % Valve/(6) Dyn. loss 0 0 %

PUMP (MECHANICAL DESIGN)

Determination of Upper Limits of Specific Speed
(Chopey, 2004)

(1) Determine upper limit of specific speed

From total head and suction head.

PUMP (MECHANICAL DESIGN)

Selection of the Best Operating Speed of Centrifugal Pump
Pump capacity = Safety Factor = Max. pump capacity = Total Developed Head, TDH = Suction Head = Upper limit of specific speed, Ns Pump stage type
s 0.5 0.75 0.5

(2) Select the best operating speed (by trials) Single-suction centrifugal pumps handle up to
5.615 m/h 10 % 6.177 m/h 44.29 m 3.44 m 3000 Single-suction pump
0.75

The value of this factor of safety can vary from a low of 5 percent of the required flow to a high of 50 percent or more. (Chopey, 2004)

0.0032 m/s at total heads up to 15 m; either single- or double-suction pumps used for the flow rates to 0.063 m/s and total heads to 91 m; beyond these capacities and heads doublesuction or multistage pumps are used. (Chopey, 2004) Obtain the value from Figure 6.10 with respective system total head and suction head. Refer to the comment at cell G55 beside TDH.

(Use: Single- or double-suction pump)

N Calculate specific /NPSH S = NQ speed,1997) (Perry, N (3) = NQ /H (Perry, 1997) s

Based on Suction Specific-Speed Ratings. Refer to Appendix. Suction specific speed rating Pump type listed by specific speed Based on Pump Types Listed by Specific Speed. Refer to Appendix

Insert trial N

Operating speed, N (r/min)

Required specific speed, Ns

Required suction specific speed, S

10000 1246 8469 11000 1371 9316 13000 1620 11010 Max 24075 3000 20389 *Remarks: 1 gpm = 0.2271 m/h and 1 ft = 0.3048 m.

Average Good Excellent Excellent

Volute, Diffuser Volute, Diffuser Volute, Diffuser Turbine

(4) Determine pump type

Operating speed selected, N = Specific speed selected, Ns =
Suction specific speed selected, S =

Type of pump stage selected Type of pump selected

11000 r/min 1371 9316 Single-suction pump Volute, Diffuser

Select the N with the best speed rating. Refer to the table above. Conversion:

1gpm 1 ft 1 in

0.2271 m/h 0.3048 m 25.4 mm

PUMP (MECHANICAL DESIGN)

(5) Determine vanes specification and number, Z (from graph)
Specific speed selected, Ns = Percent head rise from BEP to shut off = 1371 18 %
(Lobanoff, 1992) By assumption.

Obtain vanes specification from Figure 3.2 with respect to percent head rise and Ns.

Vanes specification Vanes number, Z

7 vanes 27 with droop 7

PUMP (MECHANICAL DESIGN)

(6) Determine head constant (from graph)

(7) Calculate impeller outer diameter, D2

(Lobanoff, 1992)

Obtain Ku from Figure 3.3 with respect to vanes number and Ns.

Head constant, Ku

1.03 2.08 in 53 mm
whereby H in ft.

Impeller outer diameter, D2

D2 = 1840 Ku H0.5 RPM (Lobanoff, 1992)

PUMP (MECHANICAL DESIGN)

(8) Determine capacity constant, Km2 (from graph) (9) Calculate Cm2 (10) Calculate impeller width, b2
(Lobanoff, 1992)

Cm2 = Km2 (2gH)0.5 with g = 32.174 ft/s2 (Lobanoff, 1992) b2 = GPM 0.321 (Lobanoff, 1992) (Lobanoff, 1992) Cm2 (D2 - ZSu) Estimated Su = in. (This will be confirmed during vane development and the calculation repeated if necessary.) Obtain Km2 from Figure 3.4 with respect to vanes number and Ns.
Capacity constant, Km2

0.125 12.09 ft/s 0.24 in 7 mm

Cm2 Impeller width, b2

PUMP (MECHANICAL DESIGN)

(11) Determine eye diameter:impeller OD, D1/D2 (from graph)

(12) Calculate eye area

(Lobanoff, 1992) Obtain D1/D2 ratio from Figure 3.5 with respect to Ns.

D1/D2 Eye diameter, D1

Shaft diameter under impeller eye, Ds

0.5 1.04 in 27 mm 0.3 in 8 mm 0.78 in 501 mm

Eye area

Eye area = Area at impeller eye (D1/4) - shaft are (Ds/4)

(13) Calculate suction eye velocity, Cm1 & peripheral velocity, Ut (14) Determine NPSHR (from graph)
Cm1 = GPM 0.321 (Lobanoff, 1992) (Lobanoff, 1992) Eye area (in) Ut = D1 (in) RPM 229 (Lobanoff, 1992)

Suction eye velocity, Cm1 Peripheral velocity, Ut NPSHR Nss

Nss = (RPM GPM0.5)/NPSHR0.75

11.25 3.43 49.88 15.20 12 3.66 8898

ft/s m/s ft/s m/s ft m

Obtain NPSHR from Figure 3.6 with respect to Cm1 and Ut values.

PUMP (MECHANICAL DESIGN)

(15) Determine volute velocity constant, K3 (16) Calculate volute area (As), volute width (b3) & cutwater (Lobanoff, 1992) diameter (D3)

Obtain K3 from Figure 3.8 with respect to Ns. A8 = 0.04 GPM K3 H0.5

Volute velocity constant, K3 Casing type Volute area, A8

Refer to Guidelines for Volute Width in Appendix. Refer to Guidelines for Cutwater Diameter in Appendix.

0.40 Single-volute 0.23 in 146 mm 0.42 11 2.20 56 in mm in mm

Volute width, b3 Cutwater Diameter, D3

PUMP (MECHANICAL DESIGN)

D2 = 53 mm D1 = 27 mm

INTERLOCK
Interlock System
Process interlock between V-101, V-102 and V-103 Process interlock between V-112, V-113, V-114, V-115 and V116.

Condition
V-101 or V-102 or V-103 failed closed or plugged. M-101 overfilled. P-101 malfunction. V-112 or V-113 or V-114 or V-115 or V-116 failed closed or plugged. M-102 or M-103 overfilled. P-102 or P-103 malfunction. Pipelines clogged: no flow from M-102 to M-103. V-123 or V-124 or V-125 or V-201 or V-202 or V203 failed closed or plugged. M-104 or M-201 overfilled. P-104 or P-201 malfunction. Pipelines clogged: no flow from M-104 to M-201. Buffer tank valve or V-210 or V-211 failed closed or plugged. M-202 overfilled. P-202 malfunction. Pipelines clogged.

Process interlock between V-123, V-124, V-125, V-201, V-202 and V-203. Process interlock between valve for buffer tank, V-210 and V211.

INTERLOCK (CONT)
Process interlock between V-220, V-221, V-222 and V-223. V-220 or V-221 or V-222 or V-223 failed closed or plugged. M-203 overfilled. P-203 malfunction. Pipelines clogged. V-224 or V-301 or V-302 or V-303 or V-304 failed closed or plugged. M-301 or M-302 overfilled. P-301 or P-302 malfunction. Pipelines clogged. V-305 or V-306 or V-307 failed closed or plugged. P-303 malfunction. Pipelines clogged: no flow from M-303 to HE-301.

Process interlock between V-224, V-301, V-302, V-303 and V304.

Safety interlock between V-305, V-306, V-307 and V-308