Pumps & Piping Hydraulics
Lecture-1
Objectives
Calculate & Select suitable line sizes for fluid
Work up examples of circuits
Hydraulics of a Tank-Pump-Tank Model
Calculating Hydraulic Power, NPSHa,
Determining Service of Pump (Flow/Pressure)
Estimating
Suction Speed, Efficiency, Power, Motor Rating
Recap
Driving Forces of Nature
Pressure, Temperature, Concentration,Voltage, Gravity,
Magnetic force
Material handling involved material transfer to the point
of use and run-down to storage
Material handling costs range from 30-50% of total cost in
an industry and sometime as high as 95%
Pumps transfer liquid by directly or by converting
centrifugal force/velocity to pressure
This pressure creates the potential to transfer from A to
B
Frictional Groups
R
Moody’s Friction Factor f ' 8 2
v
R
Darcy or Fanning Friction Factor fD 2 2
v
R
Stanton/Pannel
v 2
f ' 4 f D 8
Chemical Engineering - Coulson & Richardson Vol. 1, 6 ed., Ch.3, Page 66
Moody’s Diagram
Stanton’s Diagram
Chemical Engineering - Coulson & Richardson Vol. 1, 6 ed., Ch.3, Page 66
Formulae
64
Laminar f
Re
Transient 1 2.51 e
2 log
f Re f 3.7 DH
[There are other equations for fully turbulent flow. We
will use primarily this equation for calculating friction loss.
This is the Colebrook-White equation.]
http://en.wikipedia.org/wiki/Darcy_friction_factor_formulae
Bernoulli’s Equation
2 2
P1 v P2 v
z1 1
z2 hL 2
g 2 g g 2g
Liquids do not experience a significant change in density
so:
P
z hL
g
For gas, with pressure drop density also changes so
calculations require some iteration for longer runs of pipe
PM
ZRT
Pressure Drop/Head Loss
The “magical” equation filled with so many concepts!
Pf v LEq.
hL f
g 2 g DH
[Note again, if we have to calculate for gas, the pressure
drop will result in gas expansion or increasing velocity as
gas flows]
Practice #1
Calculate the pressure drop per 100 ft length in a 6” Sch-
40 carbon steel pipe in which 400USGPM of water is
flowing at 35°C (density = 62.4 lb/ft³ viscosity = 0.8cP,
Pipe ID = 6.065in, e= 0.0018in)
Q Q vD
v Re
A D2
4
Q vD
v 0.4085 2 Re 124.024
D
v= 4.442 ft/s, Re = 260621
1 2.51 e
2 log
Practice #1 contd… f Re f 3.7 DH
Take starting value of f = 0.015 f0 0.015
f1 0.017321962
f2 0.017184264
f3 0.017191724
f4 0.017191318
f5 0.01719134
For 1 ft length, Pressure Drop
P
f
2
v L
0.01719
4.442 100 1.043 ft
2
g 2g D 2 32.174 6.065
12
62.4
P 1.043 0.452 psi
144
Using Calculator (Casio 570MS/991ES etc)
Be in Computation mode Comp mode (Mode -1)
For variable memory press [Alpha] Button
A= 2.51/Re = 2.51/260621 = 9.631x10-6
B= e/(3.7D) = 0.0018/(3.7 x 6.065) = 8.0212 x10-5
F= 0.015
Type the following in the calculator
2 logA F B
2
F
To store press [Shift+Sto] button. Press enter for each iteration
Buttons
Alpha Button Mode
Shift Button Button
X Raised to the Power Y
Store
Selecting Nominal Diameter/NPS
Constraining Value or Limit Excluding
Parameter
Pressure drop per unit <1psi/100 ft [<22.6kPa/100m] High viscosity circuits
length Depressuring Circuits
Erosion Velocity ρv2 <10000 [ρv2<14884] Intermittent service,
ρv2 v<100/ρ1/2 [v<122/ρ1/2] alloys and low-abrasion
resistant metals
Settling Velocity ρv2 >100 [ρv2<148] Rule of thumb for basic
v<10/ρ1/2 [v<12.2/ρ1/2] entrainment (Different
materials have different
settling rates)
Service Velocity Specified in design practice Intermittent services
e.g <20m/s Sat. Steam
10ft/s in fire water network
Piping Specification e.g. No less than 1” Non Standard: 1.25”,
2.5”, 3”, 3.5”, 5” for
difficulty in fittings etc.
Quick Review Topics
Degree of Freedom Analysis
Tips on liquid line size estimation
Frequency & RPM
Specific Suction Speed
Pump Efficiency
Types of Drives
Piping & Instrumentation Diagrams
Sparing of Pumps
Piping Hydraulics
Solving Pressure and Flow Problems in Pipes
Flow Rate (Q) Diameter (D)
Length (L)
Density (ρ) Pressure (P1) Pressure (P2)
Viscosity (μ)
Case-1: Flow Rate is known, either pressures is calculated
Case-2: Pressures are known flow-rate is to be calculated
Practice #2
You are required to pump water at 35°C from one
atmospheric tank to the other at the rate of
400USGPM.
Data:
Suction Tank: 20m Diameter, 15m Height
Fill Tank: 30m Diameter, 20m Height
Suction Length: 60m, Discharge Length: 2000m
Vapour Pressure: 0.82psia, Density: 62.4lb/ft³,Viscosity =
0.8cP
Size the system suitable for service.
Sketch
0 psig 0 psig
20m Dia, 30m Dia,
15m Height 400gpm 20m Height
0 psig
60m 2000m
Formulae Reminder
Flow - rate (USGPM) Differenti al Pressure (psi)
Hydraulic Power (hp)
1714.3
RPM Flow Rate
1/ 2
Specific Suction Number Ns
Head 3 / 4
NPS/ID Data
ID (mm) ID (in)
NPS (in) OD (mm)
Sch-40 Sch-80 Sch-40 Sch-80
1 33.4 26.64 26.64 1.049 1.049
1½ 48.3 40.94 40.94 1.612 1.612
2 60.3 52.48 52.48 2.066 2.066
3 88.9 77.92 77.92 3.068 3.068
4 114.3 102.26 102.26 4.026 4.026
6 168.3 154.08 154.08 6.066 6.066
8 219.1 202.74 202.74 7.982 7.982
10 273.1 254.56 254.56 10.022 10.022
12 323.9 303.28 304.84 11.940 12.002
14 355.6 333.34 336.54 13.124 13.250
Margins & Motor Rating
Poles/RPM
120 Frequency
RPM
No. of Poles
Approximate Electrical Motor Speed (RPM)
Synchronous Speed
Speed with Rated Load
No. Poles (no Load)
60 hz 50 hz 60 hz 50 hz
2 Pole 3450 2850 3600 3000
4 Pole 1725 1425 1800 1500
6 Pole 1140 950 1200 1000
8 Pole 850 700 900 750
Summary
Flow: 400 USGPM
Suction Pressure: -0.9 psig
Discharge Pressure/Head: 70psig / 162 ft
Design Conditions: 400 USGPM/ 70 psig
Hydrualic Power: 16.3hp
NPSHa: 27 ft
RPM: 1500
Specific Suction Speed: 662
Efficiency/ Pump Power: 60% / 27.2 hp
Electrical Rating Margin: 25%
Electrical Rating: 34 hp
Motor Selection: 40 hp
