Piping and Pumping

Process Design

CEN 574

Spring 2004

Chemical Engineering and Materials Science

Syracuse University

Outline• Pipe routing

• Optimum pipe diameter

• Pressure drop through piping

• Piping costs

• Pump types and characteristics

• Pump curves

• NPSH and cavitation

• Regulation of flow

• Pump installation design

Piping and Pumping Learning Objectives

At the end of this section, you should be able to…

• Draw a three dimensional pipe routing with layout and plan views.

• Calculate the optimum pipe diameter for an application.

• Calculate the pressure drop through a length of pipe with associated valves.

• Estimate the cost of a piping run including installation, insulation, and hangars.

• List the types of pumps, their characteristics, and select an appropriate type for a specified application.

• Draw the typical flow control loop for a centrifugal pump on a P&ID.

• Describe the features of a pump curve.• Use a pump curve to select an appropriate pump and

impellor size for an application.• Predict the outcome from a pump impellor change.• Define cavitation and the pressure profile within a

centrifugal pump.• Calculate the required NPSH for a given pump

installation.• Identify the appropriate steps to design a pump

installation.

References• Appendix III.3 (pg 642-46) in Seider et al.,

Process Design Principals (our text for this class).

• Chapter 12 in Turton et al., Analysis, Synthesis, and Design of Chemical Processes.

• Chapter 13 in Peters and Timmerhaus, Plant Design and Economics for Chemical Engineers.

• Chapter 8 in McCabe, Smith and Harriott, Unit Operations of Chemical Engineering.

Pipe Routing

• The following figures show a layout (looking from the top) and plan (looking from the side) view of vessels.

• We want to rout pipe from the feed tank to the reactor.

Plan View

50 ft

feed tank

reactor

40 ft

steam header

35 ft

piping chase

60 ft

reactor

feed tank

piping chase

50 ft 35 ft

steam header

30 ft

45 ft

40 ft

10 ft

Layout View: Looking Down

reactor

50 ft

feed tank

reactor

40 ft

steam header

35 ft

piping chase

60 ft

Plan View= out

= in

reactor

feed tank

steam header

30 ft85 ft

20 ft

60 ft35 ft10 ft

10 ft

Layout View

Pipe Routing Exercise

• Form groups of two.

• Draw a three dimensional routing for pipe from the steam header to the feed tank on both the plan view and the layout view.

Size the Pump

globe valve

check valve

200 ft

150 ft

1. Determine optimum pipe size.

2. Determine pressure drop through pipe run.

100 gpm

Optimum Pipe DiameterThe optimum pipe diameter gives the least total cost for annual pumping power and fixed costs. As D , fixed costs , but pumping power costs .

 

Optimum Pipe Diameter

Pipe Diameter

Cos

t/(ye

ar ft

)

Total Cost

Annualized Capital Cost

Pumping Power Cost

Optimum

Example• Two methods to determine the

optimum diameter:

Velocity guidelines and Nomograph.

• Example: What is the optimum pipe diameter for 100 gpm water.

Using Velocity Guidelines

• Velocity = 3-10 ft/s = flow rate/area

• Given a flow rate (100 gpm), solve for area.

• Area = (/4)D2, solve for optimum D.

• Optimum pipe diameter = 2.6-3.6 in.

Select standard size, nominal 3 in. pipe.

Nomograph

-Convert gpm to cfm 13.4 cfm.

-Find cfm on left axis.

-Find density (62 lb/ft3) on right axis.

-Draw a line between points.

-Read optimum diameter from middle axis.

3.3 in optimum diameter

Practice Problem

• Find the optimum pipe diameter for 100 ft3 of air at 40 psig/min.

• A = (s/50ft)(min/60 s)(100 ft3/min) = 0.033 ft2

• 0.033 ft2 = 3.14d2/4

• d = 2.47 in

Piping Guidelines• Slope to drains.• Add cleanouts (Ts at elbows)

frequently.• Add flanges around valves for

maintenance.• Use screwed fitting only for 1.5 in

or less piping.• Schedule 40 most common.

Calculating the Pressure Drop through a Pipe Run• Use the article Estimating pipeline

head loss from Chemical Processing (pg 9-12).

P = (/144)(Z+[v22-v1

2]/2g+hL)• Typically neglect velocity differences

for subsonic velocities.• hL = head loss due to 1) friction in

pipe, and 2) valves and fittings.• hL(friction) = c1fLq2/d5

• c1 = conversion constant from Table 1 = 0.0311.

• f = friction factor from Table 6 = 0.018.

• L = length of pipe = 200 ft + 150 ft = 350 ft.

• q = flow rate = 100 gpm.• d = actual pipe diameter of 3”

nominal from Table 8 = 3.068 in .• hL due to friction = 7.2 ft of liquid

head

Loss Due to Fittings• K= 0.5 entrance• K = 1.0 exit• K=f(L/d)=(0.018)(20) flow through tee• K=3[(0.018)(14)] elbows• K=0.018(340) globe• K=0.018(600) check valve

Sum K = 19.5

• hL due to fittings = c3Ksumq2/d4 = 5.7 ft of liquid head loss due to fittings.

• hLsum=7.2 + 5.7 ft of liquid head loss• Using Bernoulli Equation

P = (/144)(Z+[v22-v1

2]/2g+hLsum)

P = ( /144)(150+0+12.9)= 70.1 psi due mostly to elevation. Use P to size pump.

elevation velocity friction and fittings

Find the Pressure Drop

check valve

400 ft

50 ft

400 gpm water

4 in pipe

Estimating Pipe Costs

Use charts from Peters and Timmerhaus.

Pipe

Fittings (T, elbow, etc.)

Valves

Insulation

Hangars

Installation

$/li

near

ft

Note: not

2003 $

Pumps – Moving Liquids

• Centrifugal

• Positive displacement

–Reciprocating: fluid chamber stationary, check valves

–Rotary: fluid chamber moves

Centrifugal Pumps

                       

Centrifugal Pump Impeller

Positive Displacement: Reciprocating

• Piston: up to 50 atm

• Plunger: up to 1,500 atm

• Diaphragm: up to 100 atm, ideal for corrosive fluids

• Efficiency 40-50% for small pumps, 70-90% for large pumps

Positive Displacement: Reciprocating (plunger)

Positive Displacement: Rotary

• Gear, lobe, screw, cam, vane

• For viscous fluids up to 200 atm

• Very close tolerances

Positive Displacement: Rotary

Comparisons: Centrifugal

• larger flow rates• not self priming• discharge dependent of downstream pressure drop• down stream discharge can be closed without

damage• uniform pressure without pulsation• direct motor drive• less maintenance• wide variety of fluids

Comparisons: Positive Displacement• smaller flow rates• higher pressures• self priming• discharge flow rate independent of pressure

– utilized for metering of fluids• down stream discharge cannot be closed

without damage – bypass with relief valve required

• pulsating flow• gear box required (lower speeds)• higher maintenance

Centrifugal PumpsAdvantages

• simple and cheap• uniform pressure, without

shock or pulsation• direct coupling to motor• discharge line may be closed• can handle liquid with large

amounts of solids• no close metal-to-metal fits• no valves involved in pump

operation• maintenance costs are lower

Disadvantages• cannot be operated at

high discharge pressures

• must be primed• maximum efficiency

holds for a narrow range of operating conditions

• cannot handle viscous fluids efficiently

Moving Gases• Compression ratio = Pout/Pin

• Fans: large volumes, small discharge pressure

• Blowers: compression ratio 3-4, usually not cooled

• Compressors: compression ratio >10, usually cooled.

– Centrifugal (often multistage)

– Positive displacement

Fan Impellers

Two-lobe Blower

Reciprocating Compressor

Centrifugal Pump Symbols

Pump CurvesFor a given pump1. The pressure produced at a given flow rate

increases with increasing impeller diameter.

2. Low flow rates at high head, high flow rates at high head.

3. Head is sensitive to flow rate at high flow rates.

4. Head insensitive to flow rate at lower flow rates.

Pump Curve

- used to determine which pump to purchase.

- provided by the manufacturer.

Pump Curve

Pressure increases with diameter

Low flow at high head

Head sensitive to flow at high flow rates

NPSH and Cavitation• NPSH = Net Positive Suction Head• Frictional losses at the entrance to the

pump cause the liquid pressure to drop upon entering the pump.

• If the the feed is saturated, a reduction in pressure will result in vaporization of the liquid.

• Vaporization = bubbles, large volume changes, damage to the pump (noise and corrosion).

Pressure Profile in the Pump

NPSH• To install a pump, the actual NPSH must be equal

to or greater than the required NPSH, which is supplied by the manufacturer.

• Typically, NPSH required for small pumps is 2-4 psi, and for large pumps is 22 psi.

• To calculate actual NPSH…

NPSHactual= Pinlet-P* (vapor pressure)

Pinlet = P(top of tank, atmospheric) + gh - 2fLeqV2/D

What if NPSHactual < NPSHrequired?

INCREASE NPSHactual

• cool liquid at pump inlet (T decreases, P* decreases)

• increase static head (height of liquid in feed tank)

• increase feed diameter (reduces velocity, reduces frictional losses) (standard practice)

Regulating Flow from Centrifugal Pumps

• Usually speed controlled motors are not provided on centrifugal pumps, the flow rate is changed by adjusting the downstream pressure drop (see pump curve).

• Typical installation includes a flow meter, flow control valve (pneumatic), and a control loop.

Typical Installation

FT

FC

FV

operator set-point

Designing Pump Installations• use existing pump vendor, note spare

parts the plant already stocks.

• select desired operating flow rate, maximum flow rate.

• calculate pressure drop through discharge piping, fittings, instrumentation (note if flow control is desired need to use pressure drop with control valve 50% open).

• add safety factor to calculated head – 10 psig spec pump for 20 psig, 150 psig spec pump for 200 psig.

• using head and flow rate, select impeller that gives efficient operation in region of operating flow rate.

• vertical location of pump compared to level of influent tank (NPSH).

• if want to control flow rate – spec and order flow meter and flow control valve also.