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PUMP CALCULATION GUIDELINES

1. 0 Overview:

This calculation spreadsheet was provided because I could not find a suitable pump
program within Aramco. Apparently, up till now, Aramco has been dependent on
subcontractors to provide this service. Therefore, I used the guidelines of an engineering
company that I was familiar with, Kellogg Brown and Root (KBR). The excel
spreadsheet I have provided is loosely based on an old form used by KBR.

The Aramco document that provides some Aramco pump detail is SAES-G-005.

2.0 Definitions:

 NPSH Safety Factor - This is a safety factor that is added to

 Min Flow Bypass - Sometimes pumps are run continuously and the feed flows
could be block or discontinued for periods of time. If that condition occurs and
you do not continue some forward flow, the pump would become “dead headed”
and that could damage the pump motor. To prevent that from occurring, the
designer will require a minimum flow bypass line that would be provide a
minimum flow back to the feed source of the pump. Typically this line will
include a control valve or a pressure regulator. When this piping is installed it is
called a “minimum flow bypass”.

 Minimum Flow - This is the minimum forward flow that would prevent the pump
motor from overheating and being damaged when the pump is “dead headed”.

 “Dead headed” pump – This occurs when a centrifugal pump is trying to feed a
system that is blocked so there is no forward flow. If there is now “minimum flow
bypass” piping the pump continues to try to feed the closed piping. As it does this
the motor will start to overheat and this condition would most likely damage the
pump motor. To avoid this from occurring many designs add a “minimum flow”
bypass line.

3.0 Discussion of input to spreadsheet:

The following explanations cover the areas on this form that need to be filled in. On the
spreadsheet these several areas are highlighted in blue. All other areas, not highlighted,
will automatically be filled in as you complete the highlighted areas. If you follow the
form by putting in the information as with the number on the form the form will calculate
the information you need.

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1. Pump Data (page 1)

a. Most of this data should be obtained from the current PFD’s or

information provided from the process group.

NOTE: For this calculation procedure to function properly, you must

provide a normal and a design flow rate. IF no design flow rates are
provided from process or indicated on the PFD’s, increase the normal flow
(or as Aramco forms call it: “Rated Flow”) by 20%.

b. Flow Safety Factor: Aramco has no guidelines for this safety factor.
Therefore I deferred to a standard that many engineering companies use
and that is 2 FT.

c. Efficiency: This is the estimated efficiency of the pump. Since no pump is

100% efficient and Aramco has no written guidelines for this type of
calculation, I would suggest starting with a standard pump efficiency of
20%.

d. Min Flow: This check off box is to remind you that a min flow kickback
feed rate was added to the normal feed flow rate. Many designs have
pumps running continuously with a min kickback flow. Therefore when a
kickback line is requested in your design you must determine the min flow
and add this rate to the normal feed flow rate. This is just a reminder for
you to add the minimum flow and the design feed flow into this pump
calculation.

2. Pump Suction Conditions

a. Line (1): This is the min operating pressure expected in the vessel up-
stream of the pump.

b. Line (11): Here you are determining the piping pressure loss in the feed
lines to this pump at normal and design flow rates. Initially you will need
to guess at the inlet piping based on the flow rates. What you are looking
for is a minimum pressure drop into the pumps. The limiting in sizing you
suction piping would be the delta P per 100 feet OR the overall allowable
pressure drop to the pumps. Again Aramco has no guidelines for designing
the suction lines so see the following is a suggested guideline based on
rules used by KBR.

NOTE 1: Inlet piping requirements for pumps: 0.10 to 0.5 psi/100 ft with a
maximum TOTAL pressure drop less that or equal to 2 FT of liquid.

When you select the suction piping size you will need to input the values
determined in the spaces provided. You will note that four columns have
been provided in this section. Three columns have been provided so you

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can show the suction line selected, one line size smaller than the line
selected and one line size larger. These values are provided to document
why you selected the final suction line size. The fourth line is provided for
design flow conditions for the final suction piping selected.

NOTE 2: A sketch of the inlet piping should be provided for documentation

purposes and to assist in determining the equivalent lengths. If there is any
doubt about your piping always go conservative. It is best to overestimate
lengths, fittings and distances to be assured of sizing the suction piping to this
pump.

c. Line (13): this is to be filled in IF there is equipment upstream of the

pump. This could be strainers, filters or heat exchangers. The values
inserted in the line should be obtained from the equipment manufactures
based on the normal and design flow rates. Conservative values like 10
PSI could be used if you do not have vendor information.

d. Line (15 and 16): These lines are completed only if this pump is to be a
Positive Displacement (or Recip) pump. Always leave blank for
Centrifugal pumps. A separate spreadsheet will be provided for metering
and Reciprocating pumps. Instructions for recip. pumps are detailed in
Section 5 of this document.

3. NPSH and Misc. calculation (page 2)

a. Line (2): This is the same as line (1) on page 1.

b. Line (5): As stated, this is the lowest allowed liquid level expected in this
vessel.

c. Line (6): This is the pump elevation. If you pump is near grade typically
you use 101 FT where grade is 100.

d. Line (24) NPSH Safety Factor: Aramco has no guidelines for this safety
factor. Therefore I deferred to a standard that KBR uses and that is
detailed in Table 1 of this document and varies depending up type of
pumps.

e. Line (45): The control valve mentioned here is one that maybe provided in
the feed line to your supply point. If you have a control valve in your line
then you must input a value to accommodate the control valve. A good
reference point is 10 PSI. If you have no control valve leave blank or
insert 0.

NOTE: You will have to manually input the selected pump differential by
rounding up to the next higher value of 10 and type that number into the
space provided.

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f. Max Pressure in Vessel: Typically this is the RV set pressure and is the
max possible suction pressure imposed on the pump. If atmospheric then
enter 0.

g. Max Liquid level in Vessel: Again this information should be provided on

the P&ID. Look for the level gauge information.

h. Calculated Hydraulic Horsepower: This form will automatically calculate

a hydraulic horsepower based on the input already provided. The space
provided can be filled in with the next standard size HP motor. Some
standard motor sizes are: ½. ¾,, 1 ½, 2, 3, 5, 7 ½, 10, 15, etc. A list of
standard motor sizes is attached to this document.

4. Pump Discharge Conditions:

a. Line (26): This is the pressure of the vessel, pipe or whatever location the
pump is feeding. This information must be provided by process or you can
use the gauge reading located near the injection point. Basically this is a
pressure head that the mump MUST overcome.

b. Line (29): If you have an orifice fitting in your line and you know the
setting in inches input this value in the place provided. Typically orifice
fittings are be sized for 100 inches. Sometimes this information is
provided on the P&ID or it could be found in the specification sheet for
the orifice fitting. And if it is a new fitting you could start with 100 inches.

c. Line (30): This input line is for equipment that could be in the line before
it gets to its terminal point. This could be heat exchangers, filters,
anything. If it is several pieces of equipment, I would list what they are
and put one total pressure drop. Again, if unknown, a safe number could
be 10 PSI for each piece of equipment.

d. Line (31): This could be for other items like mass flow meters. Some of
these instruments have relative large pressure drops. The values of these
pressure drops must be provided by the equipment supplier. When these
values are determined insert in this line.

e. Line (32): This is used to calculate your pressure losses in the piping to
you terminal point. You must estimate the piping lengths, number of
elbows and fittings to determine the total Equivalent Length (or Eq. Lght
as it is labeled on the form). When you select the discharge piping size
you will need to input the values determined in the spaces provided. Again
four columns are provided and are to be completed as described in the
instruction for line 11.

NOTE 1: Guidelines for sizing pump discharge piping is not specifically

addressed in the Aramco specifications. The only Aramco specifications

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mentioning, line velocities, is SAES-L-032 paragraph 5.1.2 for line sizing
criteria. In that specification it does indicate that a minimum of 3 ft/sec and a
maximum of 15 ft/sec be maintained. So that is one possible guideline.

NOTE 2: The KBR guidelines for pump discharge piping are more specific
and are summarized in the following tables. But these too are “suggested’
maximum limits for line velocities and they can be exceeded, especially for
larger line sizes. But the Delta P guidelines are still helpful.

For general purpose process pumps:

Carbon Steel Piping

Flow (GPM) Max Velocity (ft /sec) Delta P (PSI/100)
0-250 10 0.7-7
250-700 10 0.5-5
> 700 10 0.3-3

Alloy or Stainless Steel

Flow (GPM) Max Velocity (ft /sec) Delta P (PSI/100)
0-250 15 1.5-10
250-700 15 1.0-8
> 700 15 0.6-6

For Cooling and Tempered Water piping:

Headers
Line Size Max Velocity (ft /sec) Delta P (PSI/100)
36” and Smaller 15 0.3 - 0.7
36” and larger 20 0.3 – 0.7
Pump Leads ( or short branches)
Any 15 0.5 -1.5

NOTE 3: The maximum pump velocity requirements for some fluids,

including “exotic” or unfamiliar liquids should be discussed with CSD pump
specialists. Some examples of this type of process liquids are: Caustic liquids,
Concentrated H2SO4, MEA, DEA and salt water. If you have any doubt you
should contact CSD.

NOTE 4: A sketch of the estimated piping should also be provided for

documentation purpose and to assist you in determining the equivalent
lengths. If there is any doubt about your piping system always be
conservative. It is best to overestimate lengths, fittings and distances to be
assured of sizing this pump correctly.

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5. Instructions for Proportional or Reciprocating pumps.

a. To be completed at a later date.

6. At this point the Aramco forms could be completed and you should have all the
information needed to specify a pump. The information calculated on this form
can then be used to complete the following Aramco forms:

2514-ENG Rotary Positive Displacement Pumps Data Sheets

2741-ENG Centrifugal Pump Data Sheets for Horizontal Pumps and Vertical
In-line Pumps
2742-ENG Data Sheet for Centrifugal Pumps
2748- ENG ISS for Centrifugal Pumps

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TABLE 1

Requirements for completing line (24) of pump calculations

Pump Type and Service Safety Margin (Ft) Notes

BFW and BFW circulating pumps 7 5
Reduced crude vacuum tower bottom pumps 7 2, 4, 8, 9
Surface condenser hotwell pumps 1 3, 7
Cooling water pumps 2 4
Pumps is service such as absorber bottoms 7 1, 5
(with pumping temperatures < 60 deg F) and
carbon dioxide strippers (with pumping
temperatures > 400 deg F)
Any other service if NPSH requirements set 2 5
suction vessel elevation
Any other service if NPSH requirements do not 2 1, 6
set suction vessel elevation.
Proportional or reciprocating pumps 0
From Storage Tanks 2 10

TABLE 1 NOTES:

1. If dissolved gases are present, the liquid should be assumed to be at its equilibrium
pressure and temperature, i.e. vessel pressure equals vapor pressure.
2. NPSH calculations shall not consider an allowance foe use of stripping steam.
3. Total friction lose shall be limited to 1 foot of head of the liquid. The intent is to
minimize the elevation of the surface condensers because the elevation of associated
turbines and compressors is also affected.
4. Suction lines shall be sized for a unit pressure loss of less that 0.1 psi/100 feet.
5. Total friction loss shall be limited to 2 feet of head of the liquid.
6. Suction lines shall be sized for a unit pressure loss of less than 2.0 psi/100 ft.
7. These pumps shall have individual suction lines run separately from the vessel.
8. Vacuum bottoms pumps shall be located at the minimum practical distance from the
suction vessels. Preferable they shall be immediately under the vessel; vacuum
bottoms pumps shall not be located under vary piping merely to conform with the
layout of other pumps.
9. In general, vacuum bottoms pumps should not be used in common standby service
(one pump is used as a spare for two separate services). If this is unavoidable, the
primary pump is the second service must be located close to the vacuum bottoms
pumps. Vacuum bottoms service governs pump location.
10. Max Delta P should be around 0.5 PSI/100 ft.

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