Piping design project

Report of piping design project equipment design course (64441)

Submitted to:

Dr. Shadi Sawalha

Prepared by:

Adel Hanni

Marwan Dwiakat

Nedal Marei

Department of chemical Engineering An-Najah National University

October 15, 2012

2

Contents

Abstract: .......................................................................................................................................... 4

Introduction: .................................................................................................................................... 5

Theoretical back ground: .............................................................................................................. 14

Sample of calculation:................................................................................................................... 27

Results : ........................................................................................................................................ 35

Discussion:-................................................................................................................................... 47

Conclusion: ................................................................................................................................... 49

References: .................................................................................................................................... 50

Appendix:- .................................................................................................................................... 51

3

List of figures :

FIGURE 1: SHORTEST DIRECT WAY ON CONTOR LINES.................................................................................................................. 6 FIGURE 2: CENTRIFUGAL PUMP. ............................................................................................................................................ 9 FIGURE 3: CUTAWAY VIEW OF CENTRIFUGAL PUMP. .................................................................................................................. 9 FIGURE 4: GATE VALVE. ..................................................................................................................................................... 10 FIGURE 5: CHECK VALVE. ................................................................................................................................................... 10 FIGURE 6: ELBOW 90

0....................................................................................................................................................... 11

FIGURE 7: ELBOW 450....................................................................................................................................................... 11

FIGURE 8: GALVANIZED CARBON STEEL PIPES ......................................................................................................................... 13 FIGURE 9: HDPE PIPES . .................................................................................................................................................... 13 FIGURE 10 DIAMETERS V.S PURCHASE COST OF DIAMETERS (GALVANIZED CARBON STEEL SECTION) .................................................. 36 FIGURE 11: LOG (DI/DREF) V.S LOG (PURCHASE COST) FOR THE CASE DI < OR = DREF (GALVANIZED CARBON STEEL) ........................... 37 FIGURE 12:DIAMETERS V.S PURCHASE COST OF DIAMETERS (HDPE). ........................................................................................ 37 FIGURE 13LOG (DI/DREF) V.S LOG (PURCHASE COST) FOR THE CASE DI < OR = DREF (HDPE) ........................................................ 38 FIGURE 14: RELATION BETWEEN DIAMETERS VS A.C.C , A.O.C, AND T.A.C FOR C-E SECTION. ....................................................... 44 FIGURE2 1 MODY CHART ............................................................................................................................................... 52 FIGURE2 2 SECDUELE 40 ................................................................................................................................................ 52 FIGURE2 3 COST OF STEEL FITTINGS ................................................................................................................................... 53 FIGURE2 4 COST OF VSLVES FRO MANSOUR COMPANY ............................................................................................................. 54 FIGURE2 5: RELATION BETWEEN DIAMETERS VS A.C.C , A.O.C, AND T.A.C FOR A-B SECTION. ....................................................... 54 FIGURE2 6 RELATION BETWEEN DIAMETERS VS A.C.C , A.O.C, AND T.A.C FORB-C SECTION. ......................................................... 55 FIGURE2 7 RELATION BETWEEN DIAMETERS VS A.C.C , A.O.C, AND T.A.C FORD-C SECTION. ......................................................... 55

List of tables : TABLE 1: SHORT DISTANCE FOR THE TAKEN LINE IN THE SYSTEM. ................................................................................................. 35 TABLE 2: THEORITICAL D(OPTMIUM) FOR EACH SECTION. ......................................................................................................... 38 TABLE 3: PROPERTIES OF FLOW AND MATERIAL OF EACH TANK ................................................................................................... 39 TABLE 4:TANKS PARAMETERS AND COST. .............................................................................................................................. 40 TABLE 5: SECTION C-E CALCULATION OF HEAD LOSSES IN PIPES, FITTINGS ,ENTRANCE, EXIT AND POWER OF PUMP. ............................. 41 TABLE 6: SUMMARY OF ALL SECTIONS HEAD AND POWER OF PUMPS CONSUMED. .......................................................................... 42 TABLE 7 CALCULATION OF A.C.C , A.O.C, AND T.A.C FOR D-C SECTION. ................................................................................... 43 TABLE 8: EXPERIMENTAL OPTIMUM DIAMETERS FOR EACH SECTION. ........................................................................................... 44 TABLE 9: SECTIONS CMPONENT AND COST. ............................................................................................................................ 45 TABLE 10: NPSH FOR PUMPS ......................................................................................................................................... 46 TABLE 11 RESULT OF PUMPS SELECTION. ............................................................................................................................... 46 TABLE 12 TOTAL COST CALCULATION. ................................................................................................................................... 47

4

Abstract:

Piping Instrumentation and Storage Tanks project aimed to apply the principles of fluid

mechanics ( mass balance, general energy equation, fluid laws …, and many other laws ), and to

choose the proper equipment(pumps, pipes, fittings, and valves) and materials according to

customer need. To design pipes and tanks it is important to select the proper material for

construction depending on the stored material and environment to avoid corrosion as possible as.

The final output of this project is the ability of design piping system to transfer water from it is

source (A) to (B) in which a storage tank is existed with flow rate of 500m3/day, and then

transfer it to a plant location (C) at flow rate of 250 m3/day, where it used to dilute concentrated

ethanol 99% available from source D at flow of rate 100 m3/day, and diluted to 70%, then

pumped to tank E at flow rate of 150 m3/day. This system contains three tanks were made from

carbon steel, tank in the location B with diameter of 16.03 m, height of 10.69m, and thickness of

8mm which used to store water that comes from source A, another tank in the location C with

diameter of 14.88m, height of 9.22m, and thickness of 6.57mm this one used as mixing tank with

tow inputs which are 250 m3/day water from tank B and 100 m

3/day 99% ethanol from location

D, the last tank in this project in the location E with diameter of 13.52 m, height of 9.015m, and

thickness of 5.77mm used to store the final product 70%ethanol which flow from tank C , the

shortest and direct way been 3725 m , HDPE(High Density Poly Ethylene) pipes were used for

water , the optimum pipe diameter in section (A B) was(0.11m )from cost analysis, (0.12m )

from Di,opt formulas, and (0.088) from cost analysis for section (B to C), (0.0926m)from

Di,opt formulas , And Galvanized carbon steel pipes were used for ethanol for (D to C) with

optimum pipe diameter (0.038m) from cost analysis and (0.434) for Di,opt formulas and (C to

E ) pipe diameter (0.048) from cost analysis and (0.0548m ) for Di,opt formulas. After

optimization of diameters , 4 pumps were choosen.

A-B Finish Thompson (AC8)

B-C Finish Thompson (AC6)

D-C Finish Thompson (AC5)

C-E Finish Thompson (AC6)

Total cost of all project is 1,610,648.95 NIS.

5

Introduction:

The general steps for piping design is beginning with obtain specification for the system

including the fluid to be pumped, design value of the flow rate required, location of fluid source

reservoir, then determine the fluid properties including temperature, specific weight kinematic

viscosity, vapor pressure, generate a proposed piping layout including the place where fluid will

be drawn from the source reservoir, the placement of the pump ,and suction and discharge line

details with appropriate valves and fittings, determine the length of the suction and the discharge

line, then specify the pipe sizes for the suction and discharge lines. Determine the total dynamic

head ha using equations. Evaluate the total static head using equations, select a suitable pump

that can deliver at least the design flow rate against the total dynamic head at that flow rate

,compute the NPSH available for the system and insure it NPSH required .[1]

Taking an example Food Production Industry Many foods are processed through specially-

designed piping systems. Piping engineers within the food production industry might be

responsible for designing and implementing highly-regulated food processing systems to enable

large food production companies to mass produce with safety and efficiency. Because the food

production industry is so important to public health and welfare, piping engineers need to know

the constraints and other restrictions regarding types of piping system materials and related

concerns. [2]

Our duty in this project was to design a piping system with its instrumentations and storage

tanks, the detailed information’s is that water must be pumped from point A to point B at a total

amount of 500m3/day, from point B water is pumped at a rate of 250 m

3/day to a plant location at

point C where it will be used to dilute concentrated Ethanol C2H5OH (99 wt%) available at point

D and pumped at a rate of 100m3/day to (70 wt%) which will be transferred to a location at point

E at a rate of 150 m3/day

And the climate conditions were: winter temperature varies from 0 to 20°C and summer

temperature varies from 20 to 40°C.

Shortest direct line was taken for this system as shown in figure (1).

6

Piping system:

Piping systems and supports must be designed for strength and structure integrity in addition to

meeting flow, pressure drop, and pump power requirements. Careful selection of piping

materials most consider strength at operating temperature ,ductility , toughness, impact

resistance, resistance to ultraviolet radiation from sunlight ,compatibility with the flowing fluid

,atmospheric environment around ,fabrication of pipe connections and installation of valves,

fittings . [1]

piping system has many component collected together:

1) Pipes:

Pipe is a tubular section or hollow cylinder, usually of circular cross-section, used mainly to

convey substances which can flow, liquids and gases (fluids).

Figure 1: shortest direct way on contor lines.

7

Pipe are made in many materials including many metals, concrete and plastic, metallic pipes are

commonly made from steel or iron; such as, carbon steel, stainless steel or galvanized steel,

brass, and ductile iron.

Plastic tubing is widely used for its light weight, chemical resistance, non-corrosive properties,

and ease of making connections. Plastic materials include polyvinyl chloride (PVC) chlorinated

polyvinyl chloride (CPVC), fiber reinforced plastic (FRP) polypropylene (PP), polyethylene

(PE),for example. In many countries, PVC pipes account for most pipe materials used in buried

municipal applications for drinking water distribution and wastewater mains.[3]

2) Tanks

Chemical tanks are storage containers for chemicals. They come in a variety of sizes and shapes,

and are used for static storage, mixing, and transport of both raw materials and finished chemical

products.Tank in the chemical process will of necessity be made of a material resistant to that

chemical stored, it will also be designed to operate within the mechanical parameters (pressure

and temperature, erosive & corrosive) of it application parameters.. Chemical tanks may be

impacted by; heat, cold, vacuum, pressure and the nature (acidic, caustic) of the chemical to be

stored. Vertical tanks are preferred over horizontal tanks since they take up less space and are

easily supported on concrete slabs. Tank bottoms should be set in an asphalt grout for protection

from exterior corrosion. All connections at the top of a tank should be grouped in one small area

near the edge of the tank to permit servicing from a single location [4]

3) Pumps:

Are used to deliver liquids through piping systems and there is many types of pump:

A) Positive displacement

- Gear pump

Uses the meshing of gears to pump fluid by displacement. They are one of the most common

types of pumps for hydraulic fluid power applications. Gear pumps are also widely used in

chemical installations to pump fluid with a certain viscosity. There are two main variations;

external gear pumps which use two external spur gears, and internal gear pumps . [5]

8

- Rotary vane pump

It is consists of vanes mounted to a rotor that rotates inside of a cavity. In some cases these

vanes can be variable length and/or tensioned to maintain contact with the walls as the pump

rotates. [6]

-Plunger pump

A type of positive displacement pump where the high-pressure seal is stationary and a smooth

cylindrical plunger slides though the seal. This makes them different from piston pumps and

allows them to be used at high pressures. This type of pump is often used to transfer municipal

and industrial sewage [7]

B) Kinetic

-centrifugal pump

Is a rot dynamic pump that uses a rotating impeller to increase the pressure of a fluid.

Centrifugal pumps are commonly used to move liquids through a piping system. The fluid enters

the pump impeller along or near to the rotating axis and is accelerated by the impeller, flowing

radials outward into a diffuser or volute chamber (casing), from where it exits into the

downstream piping system. Centrifugal pumps are used for large discharge through smaller

heads.

Like most pumps, a centrifugal pumps converts mechanical energy from a motor to energy of a

moving fluid; some of the energy goes into kinetic energy of fluid motion, and some into

potential energy, represented by a fluid pressure or by lifting the fluid against gravity to a higher

level.[8]

9

Figure 2: Centrifugal pump.

Figure 3: Cutaway view of centrifugal pump.

4) Fittings and valves:

Elements that control the direction or flow rate of a fluid in a system typically set up local

turbulence in the fluid causing energy to be dissipated as heat. Whenever there is a restriction, a

change in flow velocity or a change in the direction of flow, these energy losses occur . in a large

system losses due to valves and fittings usually small compare with frictional losses in the

pipe[1]

Gate valve:-

Also known as a sluice valve, is a valve that opens by lifting a round or rectangular gate/wedge

out of the path of the fluid. The distinct feature of a gate valve is the sealing surfaces between the

gate and seats are planar, so gate valves are often used when a straight-line flow of fluid and

minimum restriction is desired. The gate faces can form a wedge shape or they can be parallel.

Typical gate valves should never be used for regulating flow, unless they are specifically

designed for that purpose. Gate valves are designed to be fully opened or closed. When fully

10

open, the typical gate valve has no obstruction in the flow path, resulting in very low friction loss

[10]

Figure 4: Gate valve.

Check valve:-

Clack valve, non-return valve or one-way valve is a mechanical device, a valve, which normally

allows fluid (liquid or gas) to flow through it in only one direction.

Although they are available in a wide range of sizes and costs, check valves generally are very

small, simple, and/or inexpensive.

Check valves work automatically and most are not controlled by a person or any external control.

An important concept in check valves is the cracking pressure which is the minimum upstream

pressure at which the valve will operate. Typically the check valve is designed for and can

therefore be specified for a specific cracking pressure [11]

Figure 5: Check valve.

11

Elbow - 90°

90 degree elbow, also called "90 bends or 90 ells", are manufactured as SR (Short Radius)

elbows and LR (Long Radius) elbows

This is a fitting device which is bent in such a way to produce 90 degree change in the direction

of flow of the content in the pipe. An Elbow is used to change the direction in piping and is

also sometimes called a "quarterbend".

A 90 degree elbow attaches readily to plastic, copper, cast iron, steel and lead. It can also attach

to rubber with stainless steel clamps [12]

Figure 6: Elbow 900

Figure 7: Elbow 450.

12

Fluid friction

A fluid in motion offers frictional resistance to flow. Part of energy in the system is converted

into thermal energy (heat),which is dissipated through the walls of the pipe in which fluid is

flowing .The magnitude of the energy loss is dependent on the properties of the fluid ,the flow

velocity ,the pipe size ,the smoothness of the pipe wall ,and the length of the pipe .it should be

calculated according to equations.[1]

Material of construction:-

Tanks and pipes in the chemical process must be made of a material resistant to that chemical

stored or flow through it, since the choice and use correct materials for a chemical equipment

affected by many considerations, as economic considerations, because Corrosion in chemical

process plants is a big issue that consumes billions of dollars yearly. Electrochemical corrosion

of metals is pronounced in chemical process plants due to the presence of acid fumes and other

electrolytic interactions, also it is important in the design of chemical equipment to know how

they may impact the environment .[13]

In this project, carbon steel was selected for all tanks (tank E, and tank C) and galvanized carbon

steel for pipes that used to transfer Ethanol (section D-C and section C-E.

The type of steel was used is carbon steel. And for water transfer on line (A-B-C) HDPE pipes

were used.

Carbon steel

Steel where the main alloying constituent is carbon. Steel has the ability to become harder and

stronger through heat treating, but this also makes it less ductile. Regardless of the heat

treatment, higher carbon content reduces weld ability. In carbon steels, the higher carbon content

lowers the melting point. [14]

13

Figure 8: Galvanized Carbon steel pipes

High-density polyethylene (HDPE)

Has an Excellent resistance (no attack) to dilute and concentrated Acids, bases, and Alcohols (as

ethanol), on the other hand it has Good impact resistance, light weight; very low moisture

absorption, and high tensile strength. So Good chemical resistance and high rigidity make it a

good choice for trays and tanks [15]

Figure 9: HDPE pipes .

14

Pump selection:-

This should be must taken in consider:

1) It must increase the fluid pressure from the source, P1 to the fluid pressure at the destination

point P2.

2) It must raise the level of the fluid from the source Z1 to the level destination Z2.

3) It must increase the velocity head

4) It must overcome any energy losses that occur in the system due to friction in the pipe or

minor losses.

5) The power that was calculated must be more than the real required.

Theoretical back ground:

Design of tanks:

To find Volume of liquid in the tank

VL = (Qin –Qout) ×working time ×attainment ………………..(1)

Where:

Qin: the flow inters the tank (m3/day).

Qout: the flow out from the tank (m3/day).

Working time: 7days

Attainment: 92.5%

To find height of liquid in the tank

15

VL=

× D

2 × HL ………………….(2)

Where:

VL: the volume of the liquid in the tank(m3).

D : the diameter of the tank (m).

H L: the height of liquid in the tank (m).

To find the diameter of the tank

For non mixing tank

HL = 2D ……………….(3)

For mixing tank

HL =D .. ……………..(4)

To find the height of the tank

HT = HL +

………………(5)

Where:

HT : The height of the tank (m).

To find the thickness of the tank

t =

………………….(6)

Where:

t : The thickness of the tank (m)

D i: the inside diameter of the tank (m).

16

Pi : the pressure of the liquid inside the tank (Pa).

To find the pressure inside the tank

Pi = ρ × g × HL ……………….(7)

Where:

: The density of the fluid in the tank ( Kg\ m3).

standard acceleration of gravity =9.81 m/s2

: The maximum allowable stress (MPa).

To find the total thickness with corrosion allowance

t total = t + CA …………………(8)

t total: The total thickness for the tank (m)

CA: corrosion allowance (m)

CA =2mm for steel tanks and 1mm for high density polyethylene

To find the outside diameter of the tank:

D0 = Di + 2t …………………(9)

Where:

Di: the inside diameter of the tank(m)

D0: the outside diameter of the tank(m)

t: the total thickness with corrosion allowance (m)

To find the surface area of the tank:

AT= 2(area of the base) + the side area

AT = 2 × (

+ π D0 HT ……………………(10)

Where:

17

AT : The surface area of the tank (m2).

D0: the outside diameter of the tank (m).

HT: the height of the tank (m).

T: the total thickness (m).

For Carbon steel tanks:

To find the total number of sheets required for the tanks:

No. Of sheets =

………………(11)

Where:

At: the surface area for the tank(m2)

Ash: area of the sheet = 2m2

tT: thickness of the tank(m)

t sheet: thickness of the sheet(m)

Cost of sheets = No. of sheets × cost of one sheet ………………….(12)

Where: cost of one sheet = 115 NIS

To find the cost of the carbon steel tank

Cost of the tank = Cost of installation + cost of sheets + cost of bases …………….(13)

To find the mass of the tank:

M = Vt × ρ …………………(14)

Where:

M: the mass of the tank(kg)

Vt : the volume of tank material (m3)

ρ: the density of the tank material(high density polyethylene) = 959kg /m3

18

To find the total cost of the polyethylene tank

Cost = M × price of 1 kg ………………..(15)

Price of one kg polyethylene = 8 NIS

To find the physical properties of the mixture in the tanks:

Density of mixture = ∑ xi ρi ..........................(16)

Where:

Xi: the weight percentage of the component i in the mixture(wt%)

ρi : the density of the component i in the mixture(kg/m3)

viscosity of mixture = ∑ xi µ …………………(17)

Where:

Xi: the weight percentage of the component i in the mixture(wt%)

µi : the viscosity of the component i in the mixture(kg/m3)

Determination of optimum diameter by theoretical models:

For Turbulent flow:

*Carbon steel pipes:

(

( (

………………(18)

19

*Smooth pipes:

(

( (

………………...(19)

Where:

D i,opt :optimum diameter (m)

: viscosity of the fluid (Pa.s).

: density of the fluid ( kg/m3)

Q: volumetric flow rate( m3/s).

J: the friction loss due to the fittings and bends expressed as equivalent fraction loss in a straight

pipe.

K: the cost of electrical energy(NIS/KW.h).

Hy: operating hour per year(h/year).

E: efficiency of motor and pump.

X: the purchase cost of D ref (NIS).

F: the ratio of the total cost for fittings and installation to the purchase cost for the pipe.

Kf: the annual fixed charges including maintenance expressed as a fraction of initial cost for the

completely installation pipe.

n: depend on the type and the cost of the pipe.

Determination of optimum diameter by energy loss calculations:

To find the velocity in the pipe:

20

…………………(20)

Where:

V: velocity of fluid in the pipe(m/s).

Q: volumetric flow rate in the pipe( m3/s).

A: cross sectional area of the pipe( m2).

To find volumetric flow rate in (m3/s)

…………………...(21)

Where:

Q: volumetric flow rate in the pipe( m3/s).

Q1 : volumetric flow rate in the pipe( m3/day).

To find the cross sectional area of the pipe:

…………………...(22)

Where:

A: cross sectional area of the pipe(m)

Di : inside diameter of the pipe( m)

To find the Reynold number of the fluid:

…………………..(23)

Where:

Re: Reynolds number

21

: Density of the fluid ( kg/m3)

: Velocity of the fluid ( m/s)

Di: inside Pipe diameter ( m ).

: Viscosity of the fluid ( Pa.s )

To find the friction factor for turbulent flow:

( ((

( )

(

( ) (

Where:

f :friction factor for turbulent flow

Relative roughness.

D : inside diameter of the pipe(m)

ε : pipe roughness (m)

To find the major loss in the pipe:

hLmajor = f ×

…………………….(25)

Where:

hLmajor : major loss due to friction in the pipe(m)

f: friction factor for turbulent flow.

22

L: the length of the pipe(m)

D: the inside diameter of the pipe(m)

V: velocity of fluid in the pipe(m2/S).

g: standard acceleration of gravity =9.81 m/s2.

To find the friction factor for fittings and valves(in fully turbulent zone):

For steel:

(

( ( ( )

)

(

Where:

ft: friction factor for fitting.

Relative roughness.

(

) …………………….(27)

Where:

K: resistance coefficient

equivalent length ratio.

Ft: friction factor.

To find the minor loss due to fittings and valves:

23

(

) (

Where:

hL min : minor loss due to fittings and valves (m)

K: resistance coefficient.

V: average velocity (m/s)

g: standard acceleration of gravity =9.81( m/s2).

To find the total energy loss:

HL (total) = hL major + hL minor ……………………(29)

Where:

HL (total) : total energy loss(m)

hL major : major loss (m).

hL minor : minor loss (m).

To find the total head on the pump, by applying general energy equation:

(

) (

) (

) (

) (

Where:

P1: Presser at point 1 ( kPa).

24

P2: Presser at point 2 ( kPa).

v1: velocity of the fluid at point 1 (m/s).

v2 : velocity of the fluid at point 2 (m/s).

Z1: the elevation at point 1 (m).

Z2: the elevation at point 2 (m)

hA: total head on the pump(m).

hl: total energy loss(m)

g: standard acceleration of gravity =9.81 m/s2.

To find the output power of the pump:

(

Where:

P: output power of the pump(W)

hA: head loss pump, m.

γ: specific weight (N/m3).

Q: volumetric flow rate( m3/s)

To find the input power

25

Pin =

…………………..(32)

Pin: input power(W).

Pout: output power(W).

ε : the efficiency of pump and motor.

To find the annual operating cost (AOC):

AOC = (

To find the capital cost:

Installed cost(capital cost) = X(

)n (1+F)(L) ……………….(34)

Where:

X(

)n : purchase cost of one meter of the pipe(NIS/m)

F: the ratio of the total cost for fittings and installation to the purchase cost for the pipe.

L: the length of the pipe(m)

To find the annual capital cost(ACC):

ACC =

………………(35)

To find total Annual cost(TAC):

…………………..(36)

26

To find the optimum diameter from the curve of cost:

Three curves of ACC, AOC, and TCC was constructed then optimum diameter was determined.

To find net positive suction head(NPSH):

……………………..(37)

Where:

(

hsp : static pressure(absolute) head applied to fluid(m)

P: applied pressure (Pa).

γ: specific weight(N/m3)

(

hs :elevation difference from the level of the fluid in the reservation to the pump inlet (m)

(

) (

) (

hf: head loss due to friction and minor losses in suction piping (m)

F: friction factor.

L :length of suction (m)

V: velocity of fluid in the suction(m/s)

(

)

hvp : vapor pressure head of the liquid at the pumping temperature (m)

27

Sample of calculation:

distance:

*from A to 1

(1.3*200)2+ 5

2 = X1

2

X1= 260 m

For suction from C to E :-

Flow rate to the suction (Q) = 150 m3/day.

Length of the pipe = 581.84.66 m.

Fluid density () = 851.7 (kg/m3)

Viscosity () = 0.00132 (Pa.s)

Reference diameter = 0.0523 (m) From figure (…)

Cost of electricity (K) = 0.56 (NIS/Kw.h)

Fractional loss (J) = 0.35

Operating hours per year (Hy) = 8103 hr.

Ratio of the total cost to the purchase cost (F) = 1.4

Purchase cost of Dref (X) = 79.9 (NIS/m)

Efficiency of motor and pump (E) = 0.6

Annual fixed charges (Kf) = 0.2.

Cost index n , for Di Dref …..n1 = 1.344 (n equals the slop from figure (…)

Dopt = 0.0543 m = 2.05 inch …………………………eq (19).

We take most close bigger standard diameter to 2.05 which is 2.5 inch from

schedule 40.

Design of tanks:- TANK (E)

Assumptions:-

Storage time = 7 (day).

1.3*200m

X1 5m

28

Working stress of tank's material ( ) = 135 (Mpa).

corrosion allowance for steel = 4 mm.

Density of tank material = 7870 (kg/m3).

Price of tank material = 5 (NIS/kg).

Dimensions of steel sheet = 12 m.

Volume of liquid in tank (V) = ( Qin – Qout ) * Working time * attainment.

= (150 – 0 )* 7 * 0.925

= 971.25 m3

D= 2H , H= D/2

Height of liquid (HL) = D/2

HL = 13.25 m ………………………………eq(2)

HL = D/2 = 13.25/2 = 6.76 m.

Height of the tank (HT) = HL +1/3 HL. ……………………eq(5)

= 6.76 + 1/3*(6.76)

= 9.013 m.

Internal pressure (Pi) = * HL ……………………eq(7)

= 9.81 * 851.7 *9.013

= 75.311 KPa.

Thickness of the tank (t ) =

= 3.773439mm

Thickness of the tank + corrosion environmental for steel =3.773439+ = 5.773439mm

…………………….eq(8)

Area of tank = [2*3.14(D + t/1000)^2 + (2*3.14*D +t/1000)*HT]

= [2*3.14(6.76 + 5.773/1000)^2 + (2*3.14*(6.76 + 5.773/1000)*9.013]

= 263.474 m2

Weight of steel = 1 * 2 *0.002 *7870

= 31.48 Kg

29

Weight of material = Area of tank * (t/1000) * steel

= 263.474 * (5.773 /1000) * 7870

= 11970.54 Kg

Number of sheets =

= 11970.54/31.48 = 380.258 sheets.**********

Cost of tank = (Number of sheets * Cost of steel sheet)

= 380.258 * 125

= 47532.35 NIS

Assume the foundation of the tank is a stiff soil with bearing capacity =400, and using the

structural analysis program (SAP 2000 14.2.4) both footings designed as cylindrical footings.

The first tank:

Diameter = 9.5m , height (thickness) = 0.5m

By SAP the footing needs minimum steel to carry the load above

Minimum steel = 0.5 *0.0018*1 *106 = 900 mm

2

Use 5φ16/m in both directions top & bottom steel (sum=4directions)

All steel in one direction has length of 500m/direction

500*4directions = 2000m steel (total steel length)

SO, concrete >>> volume=9.52 *π * 0.5/4 = 35.5 m

3

Cost=volume *(cost/m3) = 35.5*300 = 10632 NIS

&, steel >>> weight (Kg) = * L = 162 *2000 /162 = 3160.5 Kg = 3.2ton

Cost = weight * (cost/ton) = 3.2 *3000 = 9600 NIS

Cost of tank base = Cost of concrete + Cost of steel

= 10632 + 9600

30

= 20232 NIS

The second tank:

Diameter = 8m , height (thickness) = 0.35m

By SAP the footing needs minimum steel to carry the load above

Minimum steel = 0.35 *0.0018*1 *106 = 630 mm

2

Use 4φ16/m in both directions top & bottom steel (sum=4directions)

All steel in one direction has length of 250m/direction

250*4directions = 1000m steel (total steel length)

SO, concrete >>> volume=82 *π * 0.35/4 = 17.6 m

3

Cost=volume *(cost/m3) = 17.6*300 = 5280 NIS

&, steel >>> weight (Kg) = * L = 162 *1000 /162 = 1580 Kg = 1.6ton

Cost = weight * (cost/ton) = 1.6 *3000 = 4800 NIS

Cost of tank base = Cost of concrete + Cost of steel

= 5280 + 4800

= 10080 NIS

Total cost of tank = Cost of tank + Cost of bar's + Cost tank base

= 321937.9 + 21453.063 + 20232

= 363622.96 NIS

Piping system calculation :-SECTION C-E

At optimum diameter :-

Din of pipe 2.5 inch= 63.5 - 5.16 =58.34 mm

Flow Area = 0.001314 m2.

Pipe roughness = 0.00015 m.

Length of one pipe = 6 m.

Elevation difference = 10.093 m

31

Attainment =92.5%.

Price of one meter of pipe = 44.745 NIS.

The suction contains :-

Fitting and valves

- (2 Gate & 1 Check) valves

- 4 (90 ° standard elbow)

Friction in fully turbulent zone (fT) = 0.021

Velocity = = 0.7825 m/s ………………………eq(21)

Reynold number (Re) = 26842.63 > 4000 so it is turbulent. ……….eq(24)

= 0.02476 ………………………………..(25)

hL (major) = 16.455 m ………………….……..eq(26)

Number of Union and coupling = – 1

= 581.84/6 – 1

= 95.973

hL ( minor ) = Head loss due fitting and valve + Head loss due to coupling and union

Head loss due fitting and valve =2 * hL (Gate) + 1 * hL (Check)

+ 4 * hL ((90 ° standard elbow)

hL = 0.18233 m ………………………………(30)

Head loss due to coubling and union = 95.973 ( T * ) = 0.5932 m**********

32

h ( minor ) = 0.19618 + 0.5932 =0.78945 m ************************

Entrance loss = 0.0156 m ………………………………….(29)

Exit loss = 0.0312...........................................(29)

Total loss = hL (major) + hL ( minor ) + hL (due to coubling and union) + Entrance loss + Exit

loss

= 16.445 + 0.18233 + 0.78945 + 0.0156 + 0.0315 = 17.46388 m

Pump Calculation:-for section C--E

Pump head = Total loss + Elevation difference

= 17.46388 + 10

= 27.46388 m

NPSH (m) = hsp hs – hf - hvap

851.7*9.81= 8348.31= density*9.81

Static pressure head hsp = 101325/8348.31 = 12.1371 m

Height of liquid in the tank hs = 6.76 m

Friction loss in suction pipe = hL + Loss due to gate valve + Loss due to entrance

= hL(major)/pipe length +(0.021*8* ) +

= (16.445 /581.84)+( 0.02476 * 8 *0.7825 /2*9.81)

+ 0.5*0.7825 /2*9.81

= 0.03618 m

Vapor pressure of liquid at the pumping temperature

hvap = 2300/(9.81*851.7)= 0.2752 m

NPSH (Available ) = 12.1371 + 6.76 - 0.03618 - 0.2752

= 18.8334 m

33

Properties of pump:-

From figure (25) :-

At capacity = 4.1652 m3/s , And pump head = 26.82 m.

The impeller diameter = 11 in

The pump power = 5.5 hp

The rpm = 1450

The efficiency = 40%

NPSH (Require ) = 2 m

Total cost of suction :-

Out power = Q * * hA

= 0.001736*8355.17* hA

= 0.30389 kW

Input power =

= = 0.50648 kW

Annual operating cost = Input power *(365 day/year)*(24 hour/day)*attainment * cost of

electrical energy (NIS/ Kw.hr).

= 0.50648 * 365 *24 * 0.925 *0.6

= 2475.7514 NIS/year.

Capital cost of pipe = ( pipe cost + fitting & valves cost + coupling cost )* installation.

=( (339.66 * 44.745) + (423) + ( 5588.8))*1.23

= 26087.06897 NIS

Total cost of section = Capital cost of pipe + cost of pump + cost of tanks

= 26087.06897 + 1100 + 363622.96

34

= 390810.03 NIS.

Annual capital cost =

=

= 26054 NIS /Year

Total Annual capital cost = Annual capital cost + Annual operating cost

= 26054 + 2475.7514

= 28529.75 NIS/year

35

Results :

A) the direct and shortest way

Table 1: short distance for the taken line in the system.

Line Distance (m) Total

distance (m)

Total Length of

Piping system (m)

A-B

A-1 260

2260.5

3725.34

1-2 440

2-3 1300

3-B 260.5

B-C

B-4 151.5 352

4-C 200.5

D-C

D-5 210 531

5-C 321

C-E

C-6 170.5

581. 84 6-7 130.84

7-E 280.5

36

B) models for optimum diameter

1) Galvanized Carbon steel section

The reference diameter were getting by plotting diameters V.S purchase cost of the diameters

Figure 10 diameters V.S purchase cost of diameters (Galvanized carbon steel section)

The reference diameter from figure(11) taken as 52.3 mm .

37

Figure 11: log (Di/Dref) V.S log (purchase cost) for the case Di < or = Dref (galvanized carbon steel)

From figure (11) n1= 1.1238 for Di<Dref , and n2=1.3448 for Di>Dref.

2) High polyethylene section

The reference diameter were getting by plotting diameters V.S purchase cost of the diameters

Figure 12:Diameters V.S Purchase cost of diameters (HDPE).

38

The reference diameter from figure(12) taken as 63 mm

Figure 13log (Di/Dref) V.S log (purchase cost) for the case Di < or = Dref (HDPE)

From figure (13) n1= 1.6939 for Di<Dref , and n2=1.9556 for Di>Dref..

For each type of pipes theoretical Dopt was found and arranged in table (2).

Table 2: theoritical D(optmium) for each section.

A-B B-C D-C C-E

Pipe Material HDPE HDPE Carbon Steel Carbon Steel

Liquid Water Water Ethanol 99% Ethanol 70%

Flow rate (m3/day) 500 250 100 150

Doptimum (mm) 120 92.67 43.5 0.054

39

C) Design of tanks

Table 3: Properties of flow and material of each tank

Tank E TankC Tank B

Qin (m3/day) 150 350 500

Qout (m3/day) 0 150 250

working time (day) 7 7 7

Attainment 0.925 0.925 0.925

Type of fluid 70%ethanol 70%ethanol water

Density of fluid 851.73 851.73 998

Gravity accelartion (m/s2) 9.81 9.81 9.81

working stress (MPa) 135 135 135

cost of steel (NIS/Kg) 5 5 5

Area of steel sheet (m2) 2 2 2

Density of steel (kg/m3) 7850 7850 7850

40

Table 4:Tanks parameters and cost.

Tank B Tank E Tank C

Volume of water (m3) 1618.750 971.250 1295.000

Diameter of tank (m) 16.032 13.522 14.883

Height of liquid (m) 8.016 6.761 7.442

Height of tank (m) 10.688 9.015 9.922

Volume of tank(m3) 2157.631 1294.645 1726.143

Pressure from water (Pa) 104640.563 75323.290 82903.213

Calculated thickness (m) 0.006 0.004 0.005

Required thickness (m) 0.008 0.006 0.007

Suface Area of tank (m2) 942.07 670.19 811.86

Number of required sheets 471.0 335.1 405.9

Volume Of One Sheet (m3) 0.0164 0.0115 0.0131

Volume Of Steel Sheets

(m3)

7.74 3.87 5.33

Weight of Steel Used (Kg) 60757.887 30374.047 41879.293

%installation 0.3 0.3 0.3

Cost of Tank (NIS) 303789.433 151870.236 209396.466

installation cost (NIS) 91136.830 45561.071 62818.940

Base volume (m3) 201.872 143.613 173.971

cost of base 199853.526 142176.376 172231.110

total cost 594779.79 339607.68 444446.52

41

D) energy losses in the system

sample of calculation

For each section, head losses and power of pumps calculated as sample shown on table(5) :

Table 5: Section C-E calculation of head losses in pipes, fittings ,entrance, exit and power of pump.

ρ (Kg/m^3) 851.73 851.73 851.73 851.73 851.73 851.73 851.73 851.73 851.73

µ (N.S/m^2) 0.0013 0.0013 0.0013 0.0013 0.0013 0.0013 0.0013 0.0013 0.0013

Nominal pipe size (in) 1/2'' 3/4'' 1'' 1 1/4'' 1 1/2'' 2'' 2 1/2'' 3'' 4''Out side Diameter (mm) 21.3 26.7 33.4 42.2 48.3 60.3 73 88.9 114.3

Wall thickness (mm) 2.77 2.87 3.38 3.56 3.68 3.91 5.16 5.49 6.02

Inside Diameter (mm) 15.8 20.9 26.6 35.1 40.9 52.5 62.7 77.9 102.3

cost of nominal pipe size (Nis) 20.8 27.76 37 49.9 59.66 79.9 128 164 234.7

Cross section area of the pipe(m2) 0.0002 0.0003 0.0006 0.001 0.0013 0.0022 0.0031 0.0048 0.0082

volumetric flow reat (m^3/S) 0.001736 0.001736 0.001736 0.001736 0.001736 0.001736 0.001736 0.001736 0.001736

velosity (m/S) 8.8586 5.0628 3.1255 1.795 1.322 0.8023 0.5625 0.3644 0.2113

Roughness (m) 0.0002 0.0002 0.0002 0.0002 0.0002 0.0002 0.0002 0.0002 0.0002

the ratio (D/Є) 105.33 139.33 177.33 234 272.67 350 418 519.33 682

Reynoled number 90313 68275 53645 40654 34889 27180 22758 18318 13949

length (m) 581.84 581.84 581.84 581.84 581.84 581.84 581.84 581.84 581.84

Turbulant flow (f) fraction factor) 0.0382 0.0354 0.0334 0.0318 0.0311 0.0304 0.0303 0.0304 0.0311

Majer loss 5626.1 1286.5 364.06 86.434 39.395 11.06 4.5277 1.5371 0.4029

Ft (for fittings and valves) 0.0372 0.034 0.0315 0.029 0.0277 0.0258 0.0246 0.0232 0.0216

Le/D elbow 90 30 30 30 30 30 30 30 30 30

Le/D union & coupling 2 2 2 2 2 2 2 2 2

Le/D Gate valve 8 8 8 8 8 8 8 8 8

Le/D stop check valve(swing) 100 100 100 100 100 100 100 100 100

Le/D tee 20 20 20 20 20 20 20 20 20

K (tee) 0.7449 0.6797 0.6301 0.5795 0.5541 0.5162 0.4915 0.4637 0.432

number of union & coupling 96 96 96 96 96 96 96 96 96

K elbow 90 1.1174 1.0195 0.9451 0.8692 0.8312 0.7743 0.7373 0.6956 0.648

K union & coupling 0.0745 0.068 0.063 0.0579 0.0554 0.0516 0.0492 0.0464 0.0432

K gate valve 0.298 0.2719 0.252 0.2318 0.2217 0.2065 0.1966 0.1855 0.1728

K stop check valve 3.7246 3.3984 3.1504 2.8974 2.7707 2.581 2.4577 2.3186 2.1601

hL2(union & coupling ) 28.595 8.5219 3.0108 0.9133 0.4737 0.1626 0.0761 0.0301 0.0094

hL3(2gate valves) 2.3836 0.7104 0.251 0.0761 0.0395 0.0135 0.0063 0.0025 0.0008

hL4(check valve) 14.898 4.4397 1.5686 0.4758 0.2468 0.0847 0.0396 0.0157 0.0049

hL5 (4 elbow 90) 17.877 5.3276 1.8823 0.571 0.2962 0.1016 0.0476 0.0188 0.0059

hl (entrance) 1.9999 0.6532 0.2489 0.0821 0.0445 0.0164 0.0081 0.0034 0.0011

hl (exit) 3.9997 1.3064 0.4979 0.1642 0.0891 0.0328 0.0161 0.0068 0.0023

The total hl minor 69.753 20.959 7.4595 2.2826 1.1898 0.4116 0.1938 0.0773 0.0245

∆ Z 10.093 10.093 10.093 10.093 10.093 10.093 10.093 10.093 10.093

hA 5701.9 1316.3 381.12 98.646 50.588 21.532 14.798 11.701 10.518

Power of the pump (KW) 96.91 22.372 6.4775 1.6766 0.8598 0.366 0.2515 0.1989 0.1788

42

Table 6: summary of all sections head and power of pumps consumed.

Section Section

A-B B-C D-C C-E

HDPE size (mm) Head (m) power( KW) Head (m) power( KW) carbon steel size (in) Head (m) power( KW) Head (m) power( KW)

20 78392.99 4441.53 21612.34 612.25 0.50 2347.99 26.61 5701.90 96.91

25 26158.30 1482.06 7314.57 207.21 0.75 557.14 6.31 1316.28 22.37

32 7857.60 445.19 2243.14 63.55 1.00 173.81 1.97 381.12 6.48

40 2687.29 152.25 794.74 22.51 1.25 57.41 0.65 98.65 1.68

50 943.57 53.46 302.17 8.56 1.50 37.47 0.42 50.59 0.86

63 340.79 19.31 130.70 3.70 2.00 25.34 0.29 21.53 0.37

75 173.62 9.84 82.88 2.35 2.50 22.51 0.26 14.80 0.25

90 99.33 5.63 61.54 1.74 3.00 21.19 0.24 11.70 0.20

110 67.53 3.83 53.08 1.50 4.00 20.68 0.23 10.52 0.18

120 61.61 3.49 52.08 1.48

43

E) optimum diameter from optimization curves and pump selection

Table 7 calculation of A.C.C , A.O.C, and T.A.C for D-C section.

To determine experimental optimum diameter, following chart on figure(14) explain relation

between diameters vs A.C.C , A.O.C, and T.A.C . the lowest point on the T.A.C line represents

the optimum diameter.

Nominal size (inch) 1/2'' 3/4'' 1'' 1 1/4'' 1 1/2'' 2'' 2 1/2'' 3''

Inside Diameter (m) 0.0158 0.0209 0.0266 0.0351 0.0409 0.0525 0.0627 0.0779

Price of (1m) 20.80 27.76 37.00 49.90 59.66 79.90 128.00 164.00

Price of union & coupling 69.85 78.7 109 207.4 216.1 318.3 927 1765

Number of union & coupling 88 88 88 88 88 88 88 88

length 531 531 531 531 531 531 531 531

Cost of pipe 11044.8 14740.6 19647 26496.9 31679.5 42426.9 67968 87084

Cost of union & coupling 6146.8 6925.6 9592 18251.2 19016.8 28010.4 81576 155320

elbow 90(Nis) 15 20.34 35.7 71.04 84.87 124.1 451 564.47

elbow 45 (NIS) 70.55 79.88 91.2 194.8 257.8 310.2 393.5 874.41

gate valve(Nis) 160 230 270 320 410 700 850 950

check valve(NiS) 15 20 25 40 55 210 400 450

Number of elbow 90 2 2 2 2 2 2 2 2

Number of elbow 45 0 0 0 0 0 0 0 0

Number of gate valve 2 2 2 2 2 2 2 2

Number of check valve 1 1 1 1 1 1 1 1

cost of elbow 90 30 40.68 71.4 142.08 169.74 248.2 902 1128.94

Cost of elbow 45 0 0 0 0 0 0 0 0

Cost of gate valve 320 460 540 640 820 1400 1700 1900

Cost of check valve 15 20 25 40 55 210 400 450

cost of installation 5266.98 6656.05 8962.62 13671.1 15522.3 21688.7 45763.8 73764.9

Piping capital cost 22823.6 28842.9 38838 59241.2 67263.3 93984.2 198310 319648

anuall capital cost 1521.57 1922.86 2589.2 3949.42 4484.22 6265.61 13220.7 21309.9

annual operating cost 77612.5 18515.7 5776.16 1907.83 1245.35 842.238 747.984 704.273

Total annual cost 79134 20438.6 8365.36 5857.25 5729.57 7107.85 13968.6 22014.1

44

Figure 14: relation between diameters vs A.C.C , A.O.C, and T.A.C for C-E section.

The optimum diameter from the curve is 0.048 m with nominal size (2")

Table 8: Experimental optimum diameters for each section.

A-B B-C D-C C-E

Type of pipes H.D.P.E H.D.P.E c.steel c.steel

D optimum (mm) 110 mm 88 mm 38 mm 48 mm

Nominal size 110 mm 90 mm 1.5 inch 2 inch

45

Table 9: Sections cmponent and cost.

A-B B-C C-E D-C

Out side Diameter 110mm 90mm 2'' 1 1/2''

Inside Diameter (mm) 90 73.6364 0.0525 0.0409

Price of (1m) 45.79 30.56 79.9 59.66

Price of union & coupling 85 70 318.3 216.1

Number of union & coupling 376 376 96 88

length 2261 352 581 531

Cost of pipe 103531 10757.1 46421.9 31679.5

Cost of union & coupling 31938.8 26302.5 30556.8 19016.8

elbow 90(Nis) 85 70 124.1 84.87

elbow 45 (NIS) 85 70 310.2 257.8

gate valve(Nis) 1500 1300 700 410

check valve(NiS) 760 622.5 210 55

Number of elbow 90 3 4 4 2

Number of elbow 45 1 0 0 0

Number of gate valve 2 2 2 2

Number of check valve 1 1 1 1

cost of elbow 90 255 280 496.4 169.74

Cost of elbow 45 85 0 0 0

Cost of gate valve 3000 2600 1400 820

Cost of check valve 760 622.5 210 55

cost of installation 41871 12168.6 23725.5 15522.3

Piping capital cost 181441 52730.8 102811 67263.3

anuall capital cost 12096.1 3515.38 6854.04 4484.22

annual operating cost 10417 4391 1067.54 1245.35

Total annual cost 22512.9 7906.05 7921.58 5729.57

46

Pump selection:

Table 10: NPSH FOR PUMPS

Table 11 result of pumps selection.

Suctions hvap(m) hf(m) hs(m) Hsp(m) NPSH

A -Pump1 0.2338 0.01981 46.68 10.347 57.2806

B-Pump2 0.2338 0.1332 15.76 10.347 26.474

D-Pump3 1.085 0.07457 19.92 13.05 34.1296

C-Pump4 0.946 0.1244 9.093 12.1 22.2634

LineHead

(m)Flow (m

3/hr)

Pump

Type

Speed

(rpm)

NPSH

(m)

Price

(NIS)

A-B 67.53 20.83

Finish

Thompso

n (AC8)

3450 57.2806 9880.39

B-C 61.54 10.42

Finish

Thompso

n (AC6)

2900 26.474 6708.1

D-C 12.844 4.17

Finish

Thompso

n (AC5)

2900 34.1296 6708.1

C-E 37.47 6.25

Finish

Thompso

n (AC6)

3450 22.2634 3789.6

Total 27086

47

Table 12 Total cost calculation.

Discussion:-

In this project the first step was to determine the shortest & most direct path with a total length of

(3725 m). equipment in the chemical process must be made of a material resistant to that

chemical stored or flow through so it the suitable material for ethanol, pipes was the

galvanized carbon steel because it doesn't change properties of ethanol, it has a high resistant to

pressure , and has a high resistance for corrosion. For water , pipes of high density polyethylene

was used because it cheaper than steel and doesn't affect on water and do same thing as steel do.

All tank designed as steel tanks tank in the location B with diameter of 16.03 m, height of

10.69m, and thickness of 8mm which used to store water that comes from source A, another tank

in the location C with diameter of 14.88m, height of 9.22m, and thickness of 6.57mm this one

used as mixing tank with tow inputs which are 250 m3/day water from tank B and 100 m

3/day

99% ethanol from location D, the last tank in this project in the location E with diameter of

13.52 m, height of 9.015m, and thickness of 5.77mm used to store the final product 70%ethanol

which flow from tank C . for each tanks it was tried to design it as D=2H OR H=2D and the

lowest cost was taken for each case.

the optimum pipe diameter in section (A B) was(0.11m )from cost analysis, (0.12m ) from Di,opt

formulas, and (0.088) from cost analysis for section (B to C), (0.0926m)from Di,opt formulas ,

And Galvanized carbon steel pipes were used for ethanol for (D to C) with optimum pipe

Part Cost (NIS)

Cost Tanks(NIS) 665056.1353

Cost of Bases for Tanks(NIS) 514261.0123

cost of pumps(NIS) 27086.194

Piping capital cost(NIS) 404245.608

Total cost (NIS) 1,610,648.95

48

diameter (0.038m) from cost analysis and (0.434) for Di,opt formulas and (C to E ) pipe

diameter (0.048) from cost analysis and (0.0548m ) for Di,opt formulas

It was noticed from the above that the %error was acceptable values, this mean that the assumed

value of the frictional loss due to fittings and bends (J=0.35) was acceptable value, also the

assumed value of efficiency(50%-70%) was acceptable, on the other hand the acceptable values

of error indicate that the assumed values of the ratio of the total cost of fittings and installation to

the purchase cost for the pipe(F=1.4),and the annual fixed charge(KF=0.2) were acceptable.

According to the following rules the pumps were chosen, the total head or pressure against which

it must operate, the desired flow rate, the suction lift, and characteristics of the fluid.

Section (A B) with flow rate of 500 m3/day was the longest with 2261 m and elevation difference

57 m between A and B. So the head was 76 m with 3.64 hp so the pump used was Centrifugal

pump Finish Thompson (AC8) with maximum head 80 m and power 10 hp.

Section (B C) with flow rate of 250 m3/day and Finish Thompson (AC6), Section (D C) with

flow rate of 100 m3/day and Finish Thompson (AC5), Section (C E) with flow rate of 150

m3/day. Finish Thompson (AC6)

Centrifugal pump was selected because it is used for high capacity and moderate head

application.

The length of suction line was 1m only to reduce the friction loss and the diameter was larger

than the discharge diameter to reduce the flow velocity and allow a smooth flow of liquid to

enter the pump at high pressure to avoid creating vapor bubbles in the fluid to avoid cavitations.

The net positive suction head (NPSH) calculated for the suction line was greater than the net

positive suction head required.

The recommended velocities for the discharge should be(1-4)m/s but in this project the velocities

was ,for section (A B) 0.9101/s ,for section (B C) 0.6798 m/s, for section (D C) 0.88141m/s ,for

section ( E C) 0.8023 m/s so it was out of range its recommended to increase the flow rate in

each section.

49

Conclusion:

In this project, it is concluded that:

*The shortest and direct way from the source A to the storage tank E was 3725m which represent

length of pipes needed.

* 3 tanks were designed for this project made from carbon steel.

Tanks:

Tank B with diameter 16.032mm

Tank E with diameter 13.522mm

Tank C with diameter 14.883mm

And number of fittings which used as shown on the following table

Table 13 total number of fittings

The pumps used :

A-B Finish Thompson (AC8)

B-C Finish Thompson (AC6)

D-C Finish Thompson (AC5)

C-E Finish Thompson (AC6)

The to total cost of project is 1,610,648.95

Number of union & coupling 936

Number of elbow 90 13

Number of elbow 45 1

Number of gate valve 8

Number of check valve 4

50

References:

1) Robert L. Mott., Applied Fluid Mechanics, Sixth Edition

2) Accessed on October 11, 2012 from: http://www.ehow.com/facts_7279525_role-piping-

engineer.html

3)Accessed on October 11, 2012 from: http://en.wikipedia.org/wiki/Pipe_fitting#Steel_pipe

4)Accessed on October 11, 2012 from: http://www.dow.com/causticsoda/safety/design.htm

5) Accessed on October 11, 2012 from: http://en.wikipedia.org/wiki/Gear_pump

6) Accessed on October 11, 2012 from:http://en.wikipedia.org/wiki/Rotary_vane_pump

7) Accessed on October 11, 2012 from: http://en.wikipedia.org/wiki/Plunger_pump

8) Accessed on October 11, 2012 from: http://en.wikipedia.org/wiki/Pump

9) Accessed on October 11, 2012 from: http://www.pipetubefittings.com/pipe-fittings/coupling-

rigid.html

10)Accessed on October 11, 2012 from: http://en.wikipedia.org/wiki/Gate_valve

11)Accessed on October 11, 2012 from: http://en.wikipedia.org/wiki/Check_valve

12)Accessed on October 11, 2012 from: http://www.pipetubefittings.com/pipe-fittings/coupling-

rigid.html

13)Accessed on October 11, 2012 from:

http://en.wikipedia.org/wiki/Chemical_plant#Corrosion_and_use_of_new_materials

14) Accessed on October 11, 2012 from: http://en.wikipedia.org/wiki/Carbon_steel

15) Accessed on October 11, 2012 from: http://polymerprocessing.com/polymers/PE.html

16) Accessed on October 11, 2012 from: http://en.wikipedia.org/wiki/Ethanol_(data_page)

17)MSDS for ethanol

18)MSDS for water

19)al-susa company

20) william D.Callister,Jr.,Materials Science And Engineering An Introduction,sixth Edition

21) Accessed on October 11, 2012 from : http://nasos.nordnet.ru/calpeda/price/price-list-2008-

part1.pdf......... http://uk.calpeda.com/download.php

22) Mansour company

51

Appendix:-

Vapor

pressure(kPa)

viscosity(Pa.s) yeild strength(MPa) density(Kg/m3) at 20 0c

- 135 785 carbon steel

2.33 1.02*10-3 - 998 water

7.904 1.144*10-3 - 789 ethanol

52

Figure2 1 MODY CHART

Figure2 2 SECDUELE 40

53

Figure2 3 cost of steel FITTINGS

54

Figure2 4 cost of vslves fro mansour company

Figure2 5: relation between diameters vs A.C.C , A.O.C, and T.A.C for A-B section.

55

Figure2 6 relation between diameters vs A.C.C , A.O.C, and T.A.C forB-C section.

Figure2 7 relation between diameters vs A.C.C , A.O.C, and T.A.C forD-C section.

0

2000

4000

6000

8000

10000

12000

14000

16000

18000

20000

0

2000

4000

6000

8000

10000

12000

14000

16000

18000

20000

0 20 40 60 80 100 120 140

cost

(N

IS)

D diameter(mm)

ACC

AOC

TCC

56

Material Safety Data Sheet fro ethanol

Ethyl Alcohol, 70%

ACC# 91791

Section 1 - Chemical Product and Company Identification

MSDS Name: Ethyl Alcohol, 70%

Catalog Numbers: S75119, S75120, S556CA4

Synonyms: Ethyl Alcohol; Ethyl Hydrate; Ethyl Hydroxide; Fermentation Alcohol;

Grain Alcohol; Methylcarbinol;

Molasses Alcohol; Spirits of Wine. Company Identification:

Fisher Scientific

1 Reagent Lane

Fair Lawn, NJ 07410

For information, call: 201-796-7100

Emergency Number: 201-796-7100

For CHEMTREC assistance, call: 800-424-9300

For International CHEMTREC assistance, call: 703-527-3887

Section 2 - Composition, Information on I

ngredients CAS# Chemical Name Percent EINECS/ELINCS

64-17-5 Ethyl alcohol 70 200-578-6

7732-18-5 Water 30 231-791-2

Hazard Symbols: F

Risk Phrases: 11

Section 3 - Hazards Identification EMERGENCY OVERVIEW

Appearance: colorless clear liquid. Flash Point: 16.6 deg C. Flammable liquid and vapor.

May cause central nervous

system depression. Causes severe eye irritation. Causes respiratory tract

irritation. Causes moderate skin irritation.

This substance has caused adverse reproductive and fetal effects in humans. Warning! May cause liver, kidney and

heart damage. Target Organs: Kidneys, heart, central nervous system, liver. Potential Health Effects

Eye: Causes severe eye irritation. May cause painful sensitization to light. May

cause chemical conjunctivitis and corneal

damage. Skin: Causes moderate skin irritation. May cause cyanosis of the extremities.

Ingestion: May cause gastrointestinal irritation with nausea, vomiting and diarrhea.

May cause systemic toxicity with

acidosis. May cause central nervous system depression, characterized by

excitement, followed by headache, dizziness,

drowsiness, and nausea. Advanced stages may cause collapse, unconsciousness,

coma and possible death due to

respiratory failure.

Inhalation: Inhalation of high concentrations may cause central nervous system

effects characterized by nausea,

57

headache, dizziness, unconsciousness and coma. Causes respiratory tract

irritation. May cause narcotic effects in high

concentration. Vapors may cause dizziness or suffocation. Chronic: May cause reproductive and fetal effects. Laboratory experiments have

resulted in mutagenic effects. Animal

studies have reported the development of tumors. Prolonged exposure may cause

liver, kidney, and heart damage.

Section 4 - First Aid Measures

Eyes: Immediately flush eyes with plenty of water for at least 15 minutes,

occasionally lifting the upper and lower eyelids.

Get medical aid. Gently lift eyelids and flush continuously with water. Skin: Get medical aid. Flush skin with plenty of water for at least 15 minutes while

removing contaminated clothing and

shoes. Wash clothing before reuse. Flush skin with plenty of soap and water. Ingestion: Do NOT induce vomiting. If victim is conscious and alert, give 2-4 cupfuls

of milk or water. Never give

anything by mouth to an unconscious person. Get medical aid. Inhalation: Remove from exposure and move to fresh air immediately. If not

breathing, give artificial respiration. If

breathing is difficult, give oxygen. Get medical aid. Do NOT use mouth-to-mouth

resuscitation.

breathing is difficult, give oxygen. Get medical aid. Do NOT use mouth-to-mouth

resuscitation. Notes to Physician: Treat symptomatically and supportively. Persons with skin or eye

disorders or liver, kidney, chronic

respiratory diseases, or central and peripheral nervous sytem diseases may be at

increased risk from exposure to this

substance. Antidote: Replace fluid and electrolytes.

Section 5 - Fire Fighting Measures General Information: Containers can build up pressure if exposed to heat and/or fire.

As in any fire, wear a self-contained

breathing apparatus in pressure-demand, MSHA/NIOSH (approved or equivalent),

and full protective gear. Vapors may

form an explosive mixture with air. Vapors can travel to a source of ignition and

flash back. Will burn if involved in a fire.

Flammable Liquid. Can release vapors that form explosive mixtures at

temperatures above the flashpoint. Use water

spray to keep fire-exposed containers cool. Containers may explode in the heat of

a fire. Extinguishing Media: For small fires, use dry chemical, carbon dioxide, water spray or

alcohol-resistant foam. For large

fires, use water spray, fog, or alcohol-resistant foam. Use water spray to cool fire-

exposed containers. Water may be

ineffective. Do NOT use straight streams of water. Flash Point: 16.6 deg C ( 61.88 deg F)

Autoignition Temperature: 363 deg C ( 685.40 deg F)

Explosion Limits, Lower:3.3 vol %

Upper: 19.0 vol %

NFPA Rating: (estimated) Health: 2; Flammability: 3; Instability: 0

Section 6 - Accidental Release Measures

General Information: Use proper personal protective equipment as indicated in Section

8.

58

Spills/Leaks: Absorb spill with inert material (e.g. vermiculite, sand or earth), then

place in suitable container. Remove all

sources of ignition. Use a spark-proof tool. Provide ventilation. A vapor

suppressing foam may be used to reduce vapors.

Section 7 - Handling and Storage Handling: Wash thoroughly after handling. Use only in a well-ventilated area.

Ground and bond containers when

transferring material. Use spark-proof tools and explosion proof equipment. Avoid

contact with eyes, skin, and clothing.

Empty containers retain product residue, (liquid and/or vapor), and can be

dangerous. Keep container tightly closed.

Avoid contact with heat, sparks and flame. Avoid ingestion and inhalation. Do not

pressurize, cut, weld, braze, solder,

drill, grind, or expose empty containers to heat, sparks or open flames. Storage: Keep away from heat, sparks, and flame. Keep away from sources of

ignition. Store in a tightly closed container.

Keep from contact with oxidizing materials. Store in a cool, dry, well-ventilated

area away from incompatible substances.

Flammables-area. Do not store near perchlorates, peroxides, chromic acid or nitric

acid.

Section 8 - Exposure Controls, Personal Protection Engineering Controls: Use explosion-proof ventilation equipment. Facilities storing or

utilizing this material should be

equipped with an eyewash facility and a safety shower. Use adequate general or

local exhaust ventilation to keep airborne

concentrations below the permissible exposure limits. Exposure Limits

Chemical Name ACGIH NIOSH OSHA - Final PELs

Ethyl alcohol 1000 ppm TWA 1000 ppm TWA; 1900 mg/m3 TWA 3300 ppm IDLH 1000 ppm TWA; 1900

mg/m3 TWA

Water none listed none listed none listed

OSHA Vacated PELs: Ethyl alcohol: 1000 ppm TWA; 1900 mg/m3 TWA Water: No

OSHA Vacated PELs are listed for this

chemical. Personal Protective Equipment

Eyes: Wear appropriate protective eyeglasses or chemical safety goggles as

described by OSHA's eye and face

protection regulations in 29 CFR 1910.133 or European Standard EN166. Skin: Wear appropriate protective gloves to prevent skin exposure.

Clothing: Wear appropriate protective clothing to prevent skin exposure.

Respirators: A respiratory protection program that meets OSHA's 29 CFR 1910.134

and ANSI Z88.2 requirements or

European Standard EN 149 must be followed whenever workplace conditions

warrant a respirator's use.

Section 9 - Physical and Chemical Properties

Section 9 - Physical and Chemical Properties Physical State: Clear liquid

Appearance: colorless

Odor: Mild, rather pleasant, like wine or whis

pH: Not available.

Vapor Pressure: 59.3 mm Hg @ 20 deg C

Vapor Density: 1.59

Evaporation Rate:Not available.

59

Viscosity: 1.200 cP @ 20 deg C

Boiling Point: 78 deg C

Freezing/Melting Point:-114.1 deg C

Decomposition Temperature:Not available.

Solubility: Miscible.

Specific Gravity/Density:0.790 @ 20°C

Molecular Formula:C2H5OH

Molecular Weight:46.0414

Section 10 - Stability and Reactivity

Chemical Stability: Stable under normal temperatures and pressures.

Conditions to Avoid: Incompatible materials, ignition sources, excess heat, oxidizers.

Incompatibilities with Other Materials: Strong oxidizing agents, acids, alkali metals,

ammonia, hydrazine, peroxides,

sodium, acid anhydrides, calcium hypochlorite, chromyl chloride, nitrosyl

perchlorate, bromine pentafluoride, perchloric

acid, silver nitrate, mercuric nitrate, potassium-tert-butoxide, magnesium

perchlorate, acid chlorides, platinum, uranium

hexafluoride, silver oxide, iodine heptafluoride, acetyl bromide, disulfuryl

difluoride, tetrachlorosilane + water, acetyl

chloride, permanganic acid, ruthenium (VIII) oxide, uranyl perchlorate, potassium

dioxide.

Hazardous Decomposition Products: Carbon monoxide, irritating and toxic fumes and

gases, carbon dioxide.

Hazardous Polymerization: Will not occur.

Material Safety Data Sheet - Water©

I. PRODUCT IDENTIFICATION

Manufacturer’s Name: MOTHER NATURE, Inc.

Address: Everywhere, The World

Business Tele. #: Not available

Emergency Tele. #: Not available

Trade name:Water, Aqua pura

Synonyms: Dihydrogen Monoxide; H20

II. HAZARDOUS INGREDIENTS

NONE when compound is in the pure state.

III. PHYSICAL DATA

Boiling point (760 mm Hg): 100oC (212oF)

Melting point: 0oC (32oF)

60

Specific gravity (H2O = 1):1

Vapor pressure - 100oC (212oF) 760 mm Hg

- 0oC (32oF) 17.5 mm Hg

Solubility in water (% by wt.): 100%

% Volatiles by volume: 100%

Evap. rate (Butyl acetate = 1): Not available

Appearance and Odor:Clear liquid; No odor

IV. FIRE & EXPLOSION DATA

Flash Point: Not applicable

Autoignition Temperature: Not applicable

Flammable limits in air (% by Vol.): Not applicable

Extinguishing Media: Not applicable

Special firefighting procedures: Not applicable

Unusual Fire and Explosion Hazard: Rapid temperature rise of liquid can

result in explosive vaporization, particularly if in a sealed container.

V. HEALTH HAZARD INFORMATION

Routes of Exposure and Effects of Overexposure

Inhalation

Acute over exposure: Inhalation can result in asphyxiation and is often fatal.

Chronic overexposure: Chronic inhalation overexposure not encountered.

Skin Contact

Acute overexposure: Prolonged but constant contact with liquid may cause a mild dermatitis.

Chronic overexposure: Mild to severe dermatitis.

Skin Absorption

Acute overexposure: No effects noted.

Chronic overexposure: No effects noted.

Eye Contact

Acute overexposure: No effects noted.

Chronic overexposure: No effects noted.

Ingestion

Acute overexposure: Excessive ingestion of liquid form can cause gastric distress and mild

diarrhea.

Chronic overexposure: No effects noted.

61

Emergency and First Aid Procedures

Eyes: None

Skin: None

Inhalation: Remove to fresh air; Provide artificial respiration; Provide oxygen.

Ingestion: None

Notes to Physician: None

VI. REACTIVITY DATA

Conditions contributing to instability: Exposure to direct current electricity.

Incompatibility: Strong acids and bases can cause rapid heating. Reaction with sodium

metal can result in explosion.

Hazardous decomposition products: Hydrogen - Explosive gas Oxygen - Supports rapid

combustion

Conditions contributing to hazardous polymerization: None

VII. SPILL or LEAK PROCEDURES

Steps to be taken if material is released or spilled:

Small quantities can be mopped or wiped up with rags.

Large quantities should be directed to collecting basin or drain with dikes or

swabs.

Neutralizing chemicals

None required.

Waste disposal method:

Process contaminated material through treatment plant prior to discharge

into environment. Discharge permit may be required.

VIII. SPECIAL PROTECTION INFORMATION

Ventilation requirements:

62

Remove hot vapor from environment using local exhaust systems.

Specific personal protective equipment:

Respiratory: None required.

Eyes: Goggles or full face splash shield when dealing with hot liquid.

Hands: Use insulating gloves when extensive exposure to solid state or high

temperature liquid state is contemplated.

Other clothing and equipment: Use heat protective garment when exposed to

large quantities of heated vapor.

IX. SPECIAL PRECAUTIONS

Precautionary statements:

Compound readily exists in all three phases at atmospheric pressure. Phase

changes occur over a narrow (100oC/212

oF) temperature range.

Compound is known as "the universal solvent" and does dissolve, at least to

some extent, most common materials.

Compound will conduct electricity when dissolved ionic solutes are present.

Other handling and storage requirements:

A high pressure containment vessel should be used for the vapor at high

temperatures.

Do not allow filled, closed containers to solidify as compound expands upon

freezing.