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0.05256 m3/s
7.05 m
Figure 1. Pump Operating Failures [2] Discharge Head [H] 6.29 bar
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Pump System Pressure Losses ∆𝑃 =
. × × . × .
= 0.0053 𝑏𝑎𝑟 (5)
× .
The pump operating point is the point where the
system resistance curve intersects the pump The results for suction side pressure drop can be
performance curve. This can be understood as, summarized as,
for a given flow rate, the resultant pump head Table 7. Suction Side Frictional Losses
arrived at, after accounting for all the static and
Parameter Value Unit
dynamic losses (represented as system
resistance) from the generated pump Total Reynolds Number [Re] 329,372 -
Dynamic Head (TDH).
Flow Behaviour Turbulent -
The factors contributing to system resistance is,
Friction Factor Equation Swamee-Jain -
1. Suction Piping & Fittings Frictional Loss
Friction Factor 0.0163 -
2. Discharge Piping & Fittings Frictional Loss
Suction ε/D 0.00022 -
3. Control Valve Pressure drop
Pressure Drop [ΔP] 0.0053 bar
4. Total Static Head
Suction & Discharge Frictional Pressure Losses The calculations are similarly performed for
To estimate the total static head, the worst case discharge side with a discharge side velocity of
scenario of Low Low Liquid Level (LLLL) in the 2.82 m/s and the results are summarized below,
suction vessel & High High Liquid Level (HHLL) in Table 8. Discharge Side Frictional Losses
the receiving tank is considered. This is taken so Parameter Value Unit
to ensure that during LLLL, the pump does not
suffer from cavitation due to Net Positive Suction Reynolds Number [Re] 433,408 -
Head (NPSH) deficiency, i.e., even during LLLL, Flow Behaviour Turbulent -
NPSHA > NPSHR. To estimate NPSHA, the suction
line frictional pressure drop is calculated using Friction Factor Equation Swamee-Jain -
the Darcy-Weisbach equation (Appendix B). The Friction Factor 0.0165 -
Suction Velocity (VS) is estimated as,
. Suction ε/D 0.00029 -
𝑉 = = ≈ 1.63 𝑚/𝑠 (2)
.
Pressure Drop [ΔP] 2.123 bar
The Suction Side Reynolds Number is,
. × . × .
Total Static Head
𝑅𝑒 = = 329,372 (3)
. The total static head is computed as,
As the calculated suction side Reynolds number is [( ) ( ) ]× ×
∆𝑃 = (6)
much higher than 4000, the flow is well into the
turbulent region. The friction factor can now be ∆𝑃 =
[( ) ( . )]× . × .
≈ 0.27 𝑏𝑎𝑟 (7)
calculated using Colebrook equation but owing to
its implicit nature, the friction factor is calculated Therefore the pump’s NPSHA is calculated as,
using Swamee-Jain correlation (Appendix B), 𝑁𝑃𝑆𝐻 = 𝑃 + 𝑃 − 𝑃 − 𝑃 (8)
.
𝑓= . . = 0.0163 (4) 𝑁𝑃𝑆𝐻 = 0.27 + 1.04 − 0.023 − 0.0053 (9)
. .
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The calculated NPSHA is 1.23 bara and is higher .
than NPSHR of 0.69 bara. The pump suction 𝐹 = 1+ = 0.9216 (26)
pressure is calculated as,
. .
(ℎ𝐿𝐿𝐿𝐿 +ℎ𝑒𝑙𝑒𝑣 )𝑉𝑒𝑠𝑠𝑒𝑙 ×𝜌×𝑔 𝐹 = + = 0.8197 (27)
𝑃 =𝑃 + − 𝑃 (11) .
105
The inlet pressure in psig for choke flow equation
(0.25+2)×997.8×9.81
𝑃 = 1.04 + − 0.0053 (12) is calculated as by considering pressure drop
105
between Pump Discharge and Control valve Inlet
𝑃 ≈ 1.25 𝑏𝑎𝑟𝑎 (12.78 𝑚) (13)
is very small as,
The Pump Discharge Pressure for the flow rate of
𝑃 = (7.54 × 14.7) × 14.7 = 96.1 𝑝𝑠𝑖𝑔 (28)
189.2 m3/h & corresponding pump head of 6.29
bara is calculated as, 𝑃 = 96.1 − (3.59 × 14.7) = 43.4 𝑝𝑠𝑖𝑔 (29)
∆𝑃 = 87 𝑝𝑠𝑖 (34)
𝑃 = 𝑃 + 𝑃 + ∆𝑃 + ∆𝑃 (17)
Since Psizing PChoked, then Psizing = 53 psi
∆𝑃 = 7.54 − 2.123 − 0.27 − 0.5 − 0.04 −
. × .
1.02 ≈ 3.59 𝑏𝑎𝑟𝑎 (18) 𝐶 = = 124.3 𝑔𝑝𝑚/ 𝑝𝑠𝑖 (35)
× .
Total Dynamic Losses .
The total dynamic losses is computed as, Reinserting the calculated Cv value of 124.3, the
value of Fp, FLP and new Cv is re-computed
𝑇𝐷𝐻 = 𝑃 + 𝑃𝑠 + ∆𝑃𝑚 + ∆𝑃𝑒 + ∆𝑃𝐶𝑉 (19) iteratively,
𝑇𝐷𝐻 = 0.005 + 2.12 + 0.27 + 0.5 + 0.04 + Table 9. FP, FLP & Cv Iterations
3.59 ≈ 6.52 𝑏𝑎𝑟𝑎 (20)
Iteration FP FLP Cv
Control Valve Cv Required
1 0.92 0.82 124.3
The required Cv of the control valve is calculated
by estimating the valve coefficients first followed 2 0.98 0.82 117.4
by checking if choked flow exists (Appendix A), 3 0.98 0.82 117.1
𝐾 =1− =1− .
= 0.937 (21) 4 0.98 0.82 117.1
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Therefore for a flow of 189.2 m3/h, the Cv control valve. If there are no fittings, Fp is taken
required is 117.1 gpmpsi. For the 4” valve to be 1.0. The term K is the algebraic sum of the
selected, the % Cv becomes velocity head loss coefficients of all the fittings
. that are attached to the control valve & is
%𝐶 = = 49.6 % (36)
estimated as,
Pump Operating Envelope ∑𝐾 = 𝐾 +𝐾 +𝐾 −𝐾 (38)
To generate the pump operating envelope, the
Where,
above set of calculations is performed for various
% Cv between 20% to 80% to estimate the total K1 = Upstream fitting Resistance Coefficient [-]
dynamic head at various flows. Below is the K2 = Downstream fitting Resistance Coefficient [-]
pump performance curve that includes the
KB1 = Inlet Bernoulli Coefficient [-]
system resistance curves for various % Cv & flow
rates. KB2 = Outlet Bernoulli Coefficient [-]
Where,
𝐾 =1− (39)
𝐾 =1− (40)
Where,
D1 = Pipe Inlet Diameter [in]
D2 = Pipe Outlet Diameter [in]
If the upstream and downstream piping are of
Figure 3. Pump Operating Envelope equal size, then, KB1 = KB2, and therefore, are
Appendix A – Liquid Control Valve Sizing [1] dropped from the ΣK equation. If the
Based on ANSI/ISA S75.01.01 Standards, to size downstream pipe size is similar to upstream pipe
the control valve, the following Liquid control size, i.e., D1 = D2, then KB1 = KB2. The most
valve sizing set of equations can be used, commonly used fitting in control valve
installations is the short-length concentric
Step 1: Calculate Piping Geometry (Fp) & Liquid
reducer. The equations for these fittings are,
Pressure Recovery Factor (FLP)
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Appendix D – Liquid Control Valve Sizing
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