Pump and Hydraulic Calculation Total Static Head (h, m) is different elevation between suction head and delivery head.

Suction Head (hs, m) is elevation different from minimum possibility of water surface level to center line of suction pump. (- when reference point higher than suction pump, + when reference point lower than suction pump) Discharge Head or Delivery Head (hd, m) is elevation different from maximum possibility of water surface level to center line of discharge pump. Absolute Static Head (h, m)

Net Head (hnet, m) is power in term of water height. Manometric Head (hm, m) is actual head which pump can create, by checking thought pressure gauge.

Which, normally hm < h Hydraulic Power (HP, W) is the theory power for liquid transportation.

Where Q = Flow Rate (m3/s) Break Power or Shaft Power (BP, W) is power input to pump which related with pump efficiency (ηp)

Drive Power (DP, W) is power input to motor drive which related with motor efficiency (ηD)

Hydraulic Efficiency (ηhyd) or Manometric Efficiency (ηmano) is the ratio of actual head with theory head.

Overall Efficiency (ηo) is the ration of theory power with actual power.

Where γ =Specific Weight = gρ (N/m3) P = Drive power (W)

Energy Equation (Bernouli’s Equation)

Where P1 = Pressure from 1 st reference point (Pa) P2 = Pressure from 2 nd reference point (Pa) Z1 = water level from 1st reference point (m) Z2 = water level from 2nd reference point (m) V1 = Decreasing velocity of 1st reference point (m/s) V2 = Increasing velocity of 2nd reference point (m/s) hP = Power receiving from pump (m) hL = Power lose from piping and fitting (m) (if either size of 1 st reference or 2 nd reference are larger than 10 times of pipe diameter, V1 and V2 can be negligible) Net Head (hnet, m) under Bernouli’s equation is the following.

Net Positive Suction Pressure (NPSH) is the net suction pressure after minus suction loss and vapour pressure. NPSH consist of NPSHA and NPSHR

NPSHA (available net positive suction head, m) can be calculated from the actual location.

Basis 1st reference point is bigger than suction pipe more than 10 times, V1 = 0 m/s and P2 must more than Pv to protect cavitation (P2 > Pv) then

Where Pv = Vapour Pressure (Pa) NPSHR (Required net positive suction head, m) this value will get from manufacture but, anyway, roughly a calculation for expedition pump characteristic is;

Where N = revolution (rpm)

S = Specific suction velocity

Recommendation NPSHA for pump selection.

Cavitation is main problem about pump such as abnormal sound, vibration, corrosion and less performance. Cavitation can be occurred generally two styles, one is throatting in pipe and the other one is loss suction pump. Cavitation in pipe (throatting) From Bernouli’s equation

Assume that pipe is in same elevation then Z1 = Z2

Flow rate is constant but velocity is related with pipe size. And pressure which can cause cavitation is vapour pressure. From which Pgauge = P2

Then

Cavitation incase loss suction pump

From Bernouli’s equation

Assume that V1 = 0 m/s, Z1 = 0 m (reference point) and hp is not available. Then

Where V2 = Vs = Suction velocity (m/s) hfs Suction Friction Loss (m) Note The result, hs is the theory maximum allowable height (deep) for suction pipe. The other method for checking the height (deep) and pump are suitable properly, or not, by checking Thoma cavitation coefficient (σ). Thoma Cavitation Coefficient (σ)

and Critical Thoma Cavitation Coefficient (σc)

Criteria Cavitation will happen when Friction loss (hL or hf, m) is loss from pipe length (main-loss) and any fitting (minor loss). Calculation method is found many formulas. - Equivalent pipe length and graph Williams-Hazen

Using method graph Williams-Hazen. 1. Count all the fitting (ex. Valve, elbow, etc) 2. Mark the point on the graph, x-axial presented flow

rate (m3/min) and y-axial present friction loss per 100 m. (hL)

- Darcy-Weisbach Equation (Moody-Chart or Colebrook Equation or Haaland Equation)

Using method Moody-Chart (for calculation main-loss) 1. Darcy-Weisbach Equation

Where f= Friction factor which can be found from Moody-Chart or Colebrook’s equation or Haaland’s equation. 2. Moody-Chart is presented the relation of Reynolds

number (Re), Relative roughness (ε/d) and Friction factor.

Where

Re = Reynolds number = or

ε = Pipe roughness (ft, mm) Where μ = Dynamic Viscosity (kg/m.s, N.s/m2)

υ = Kinematics Viscosity = (m2/s)

Pipe roughness (ε, ft or mm)

3. Colebrook’s equation

But the Colebrook’s equation has some difficulty about verify f-value by trial and error method.

4. Haaland’s Equation

Appling method of Moody-Chart (for calculation main-loss and minor-loss) 4. Darcy-Weisbach Equation will become

Where Ki = minor-loss coefficientV = Velocity (m/s) Because of minor-loss head from

K-Value can be checked from “Resistance coefficient chart” as attachment.

Minimum Required Flowrate (MF, m3/hr) Min-flow is the required flow rate to pump for protection the liquid temperature increasing. (Assume temperature rises less than 15oC)

Which, normally, this value will be provided by manufacture.

Pump Specific Speed (Ns, dimensionless) Pump specific speed is used for impeller selection or estimate pump efficiency (%)

Viscosity Correction, This method is applied for high viscosity pump which can be predicted by multiply correlation factor with water pump.

Where = Capacity of pump when use with water

= Head of pump when use with water

= NPSH of pump when use with water

= Water pump Efficiency

The correlation equations are following.

Piping, General recommendations for good design practice. - Branches of suction pipe

This is kind of manifold, to protect the interference the following criteria should be considered.

1. Vm = Manifold velocity ≤ 0.6 0.9 m/s 2. Suction length (Ls) ≥ 10.Ds (suction diameter) 3. Vs = Suction Velocity ≤ 1.5 m/s

- Suction sump

WL = Water Level

The detail for calculation suction sump is presented by the other documents.

Pump System consists of two type, parallel and series.

- Parallel System

QT Q1+Q2

QT 1.1Q1 (Depend on system loss)

- Series System

HT H1+H2

Sometime, total series flow more than parallel flow. It depends on system loss, mean downstream friction loss.

Conclusion to get the higher flow

Big pipe (low hf) – Parallel is advantage. Small pipe (high hf) – Series is advantage. System Loss Equation This formula is provided for head-loss-curve presentation which can be applied for checking the following. 1. Performance curve, operation point 2. Estimate total flow of parallel or series system

Q = Flow rate (m3/min)

Affinity Law To safe the power consumption, adjusting revolution

is the other choice except pipe loss reduction.

Where Subscribe n = New and o = Old The other way to change pump performance is the cutting impeller. This method might use for reduce downstream pressure.

Where D2 = Diameter of impeller (mm)

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