ENCH 4290 – Intro to Chem. Eng.
Design
Oct. 7th, 2015
University of Tennessee - Chattanooga
1 .
What You Should Learn
Pump Design Details
Review of Mechanical Energy Balance
Pipe Sizes
Pump Types
Net Positive Suction Head (NPSH)
Pump and System Curves
Pump Design Details
Pumps move material through process
How do I pick one?
What does the process require?
Flow Rate
Pressure (Head)
Constant or Variable Flow
Pump Design Details (cont.)
What limitations does the process have?
Hazardous material
Sensitivity of the material to shear, other agitation
Is the material abrasive?
Viscosity
Temperature
Suction Lift
There are two fundamental styles: centrifugal and
positive displacement
Mechanical Energy Balance
∆𝑃𝑃 ∆𝑣𝑣 2
+ + 𝑔𝑔∆𝑧𝑧 + 𝑒𝑒𝑓𝑓 − η𝑃𝑃 𝑤𝑤𝑠𝑠 = 0
𝜌𝜌 2
2𝑓𝑓𝑓𝑓𝑣𝑣 2
𝑒𝑒𝑓𝑓 = (Fanning friction factor)
𝑑𝑑
You may have learned Moody friction factor
Fanning friction factor = Moody friction factor/4
Energy Balance (cont.)
Across pump: η𝑃𝑃 𝑤𝑤𝑠𝑠 = ∆𝑃𝑃/𝜌𝜌
∆𝑃𝑃 2𝑓𝑓𝑓𝑓𝑣𝑣 2
In pipe: = −
𝜌𝜌 𝑑𝑑
Must include gΔz if elevation change
Static vs. Friction Head
Pumps vs. Compressors
Pump less expensive and thus equipment of choice
Why?
ρliquid ≈ 1000ρgas
Therefore, work is much greater for compressor
Typically only use compressor if liquid phase not
possible
E.g. air or other non-condensables
Frictional Pipe Flow
Need expression for friction factor
Can use Moody diagram
Difficult for some problems
Also not accurate
There are also charts (example for water)
Laminar
16 16𝜇𝜇
𝑓𝑓 = =
𝑅𝑅𝑅𝑅 𝜌𝜌𝜌𝜌𝜌𝜌
Frictional Pipe Flow (cont.)
Turbulent
Colebrook
1 ∈/𝐷𝐷 1.255
= −4𝑙𝑙𝑙𝑙𝑙𝑙10 +
𝑓𝑓 3.7 𝑅𝑅𝑅𝑅 𝑓𝑓
Pavlov
0.9
1 ∈/𝐷𝐷 6.81
= −4𝑙𝑙𝑙𝑙𝑙𝑙10 +
𝑓𝑓 3.7 𝑅𝑅𝑅𝑅
Moody Diagram
Geankoplis Figure 2.10-3 pg. 94
Friction
Nom. dia. Inside dia. Flow rate head loss (ft
(in) (in) (gpm) of head per
ft pipe)
¼ 0.311 2.4 2.15
½ 0.527 6.8 1.08
¾ 0.745 13.6 0.69
1 0.995 24 0.48
1½ 1.600 63 0.26
2 2.067 105 0.19
2½ 2.469 149 0.15
3 3.068 230 0.117
4 4.026 400 0.084
6 6.065 900 0.051
8 8.125 1615 0.036
10 10.250 2570 0.027
12 12.250 3675 0.022
14 13.500 4460 0.0194
For water only; based on 10 ft/s velocity
Chart Example
Types of Problems
Find ws or ΔP
Given v, μ, ρ, D, L, ε
Calculate Re and ε/D and use Moody diagram to find f
Alternately, use appropriate equation or table
Then use mechanical energy balance (MEB)
Types of Problems
Find velocity or flowrate
Cannot calculate Re since v is unknown
Use Moody diagram with trial-and-error
Or use appropriate equation and solve simultaneously with
MEB for f and v
Find diameter
Cannot calculate Re since D is unknown
Similar approach to above
Elbows, Fittings, etc.
How to account for frictional losses due to elbows,
fittings, valves, expansion/contraction
Two methods
Equivalent length method
Velocity heads method (K factor)
Pipes
Heavy walls, 20-40 ft lengths
Metallic – can be threaded
Connected by fittings (welded, flanged, screwed)
Schedule number
For 2 in, schedule-40 pipe, what dimension is 2 in?
Schedule # = 1000(P/S)
P = service pressure (psi)
S = allowable stress (psi)
Pipes (cont.)
Schedule # ≈ 1000t/R
t = wall thickness
R = radius
Both in inches
Typical Velocities in Pipes
Gravity flow: 0.5 – 1 ft/s
Pump inlet: 1 – 3 ft/s (0.3 – 1 m/s)
Pump discharge: 4 – 10 ft/s (1 – 3 m/s)
Also applies for typical pipe
Steam: 30 – 50 ft/s (10 – 20 m/s)
Air/gas: 30 – 100 ft/s (10 – 30 m/s)
Velocities in Pipes (cont.)
Do not want to exceed maximum recommended values
for extended period of time
Leads to erosion (physical wear)
Do not confuse with corrosion (chemical wear)
Pump Types (cont.)
Centrifugal
“Constant Head”
Spinning impeller applies centrifugal force on liquid,
giving it the energy to move
Great for general duty
Generates low ΔP
Pump Types (cont.)
Centrifugal
Pump Types (cont.)
Positive displacement
“Constant volume”, “constant flow”
Pump creates cavity then physically forces fluid through
the pipe
Must create relief systems or recycle because you cannot
“deadhead” them
Generates large ΔP
Great for high viscosity materials
Pump Types (cont.)
Positive displacement
Pump Types (cont.)
Issue Centrifugal Positive Displacement
Best choice for large
Flow Rate
flow rates
Pressure Generates highest pressures
Constant or Can control easily with Constant flow; can control
variable flow control valve by varying motor speed
Seals are problem area;
Hazardous
can consider magnetic Easier to isolate material
materials
drive
Need to consider Good for shear sensitive
Material sensitivity
impeller material
Not great for high
Viscosity Best for high viscosity
viscosity
Temperature Need to consider elastomers
Suction Lift May need to be primed Self-priming
NPSH
Net Positive Suction Head
Pressure decreases as fluid enters pump prior to
mechanism that increases pressure
If fluid too close to vapor pressure at pump inlet, it can
flash upon entering pump
Called cavitation
Can cause long-term damage
Cavitation
NPSH (cont.)
NPSHA = Pinlet – P*
NPSHA = NPSH “available”
NPSHR = NPSH “required”
Information supplied by
pump manufacturer
NPSH (cont.)
Typical situation
𝑃𝑃2 −𝑃𝑃1 2𝑓𝑓𝑓𝑓𝑣𝑣 2
− 𝑔𝑔𝑔 + =0
𝜌𝜌 𝐷𝐷
2𝜌𝜌𝜌𝜌𝜌𝜌𝑣𝑣 2
𝑃𝑃2 = 𝑃𝑃1 + 𝜌𝜌𝜌𝜌𝜌 −
𝐷𝐷
𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝐴𝐴 = 𝑃𝑃2 − 𝑃𝑃∗
2𝜌𝜌𝜌𝜌𝜌𝜌𝑣𝑣 2
𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝐴𝐴 = 𝑃𝑃1 + 𝜌𝜌𝜌𝜌𝜌 − − 𝑃𝑃∗
𝐷𝐷
𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝐴𝐴 = 𝑎𝑎 − 𝑏𝑏𝑣𝑣̇ 2 (general form)
NPSH (cont.)
NPSH (cont.)
How to increase NPSHA?
𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝐴𝐴 = 𝑎𝑎 − 𝑏𝑏𝑣𝑣̇ 2
𝑎𝑎 = 𝑃𝑃1 + 𝜌𝜌𝜌𝜌𝜌 − 𝑃𝑃∗
32𝜌𝜌𝜌𝜌𝜌𝜌
𝑏𝑏 =
𝜋𝜋2 𝐷𝐷5
Increase a
Increase h, increase P1, or decrease P* (decrease T)
Decrease b
Decrease L, increase D
Suction line usually larger D
Pump Curves
Supplied by
manufacturer
Centrifugal – aka
“constant head”
Positive displacement –
aka “constant volume”
Pump Curves
ℎ𝑡𝑡𝑡𝑡𝑡𝑡://𝑤𝑤𝑤𝑤𝑤𝑤. 𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚. 𝑐𝑐𝑐𝑐𝑐𝑐/𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏/ℎ𝑜𝑜𝑜𝑜 − 𝑡𝑡𝑡𝑡 −
𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟 − 𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝 − 𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝 − 𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐/
System Curves
∆𝑃𝑃1−2 = ∆𝑃𝑃1−3 + −∆𝑃𝑃𝑓𝑓𝑓𝑓 + −∆𝑃𝑃2−3
Δ = out – in
ΔP1-3 = source to destination ΔP (usually > 0) plus
ρgΔz (could be > 0 or < 0)
ΔP1-2 = pressure change across pump (> 0)
ΔPfr = frictional pressure drop in pipes (< 0)
ΔP2-3 = frictional pressure drop across valve (< 0)
System Curves
∆𝑃𝑃𝑠𝑠𝑠𝑠𝑠𝑠 = ∆𝑃𝑃1−3 + −∆𝑃𝑃𝑓𝑓𝑓𝑓
∆𝑃𝑃𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝 = ∆𝑃𝑃𝑠𝑠𝑠𝑠𝑠𝑠 + −∆𝑃𝑃𝑣𝑣𝑣𝑣𝑣𝑣𝑣𝑣𝑣𝑣
For ΔPsys, again obtain general form:
∆𝑃𝑃𝑠𝑠𝑠𝑠𝑠𝑠 = 𝑎𝑎 − 𝑏𝑏𝑣𝑣̇ 2
𝑎𝑎 = ∆𝑃𝑃1−3
32𝜌𝜌𝜌𝜌𝜌𝜌
𝑏𝑏 =
𝜋𝜋2 𝐷𝐷5
Often expressed as head (divide through by ρg)
System Curves (cont.)
What You Should Have Learned
Pump Design Details
Review of Mechanical Energy Balance
Pipe Sizes
Nominal pipe size vs. actual dimensions
Pump Types
Centrifugal vs. positive displacement
Advantages/disadvantages
What You Should Have Learned
Net Positive Suction Head (NPSH)
Cannot be too close to vapor pressure at pump inlet,
leads to cavitation and damage
Increasing elevation, reducing friction, or cooling pump
inlet helps
Pump and System Curves
How to obtain, interpret and use
Can always buy pump that is needed
Flexibility in operation determined by pump curve
