Method Statement – Sludge Pumping & Piping Design

Contents
1. Introduction:........................................................................................................................................2
2. Slurry Piping.........................................................................................................................................2
3. Slurry Pump.........................................................................................................................................3
4. Execution Plan:....................................................................................................................................4
5. Software’s / Design Tools....................................................................................................................4
6. Time Duration:.....................................................................................................................................5
7. Technical Team Details........................................................................................................................5
 Method Statement – Sludge Pumping & Piping Design

1. Introduction:

Project scope is to design the Slurry Transfer system comprising of Slurry Pumps and Piping from existing
plant facility to Tailing Dam.

Slurry consists of Fine and Course particles, they will be separated in Cyclone separation system and fine
slurry is transferred to tailing dam and coarse slurry is transferred for back filling after mixing it with
cement in Mixers.

Current installation is only compromising of slurry transfer to Tailing dam with a valve manifold
(diversion for backfilling for future).

2. Slurry Piping
Slurries containing solid particles essentially coarser than 50 microns are transported in suspension by a
liquid in a pipe, providing the average velocity, V is no less than the limiting settling velocity V L. At any
velocity below VL, solids are deposited in the pipeline. This results in increased pipeline friction head
loss, with reducing flow rate and may lead to a blockage of the pipeline.

In order to determine VL accurately, it is necessary to conduct tests with the slurry on a pipeline test rig.
As a practical alternative, where this is not possible, the V L may be established by a skilled specialist or
estimated by one of the following methods, each based on Durand’s formula:

Durand’s Formula VL = FL √2gd(S - Sl) / S1

 Method Statement – Sludge Pumping & Piping Design

3. Slurry Pump

Slurry pump is a general term for a pump that handles abrasive slurry. They may be considered an end
suction pump, vertical column pump, or submersible pump.

Key Features:

Pumps are constructed either of high nickel cast iron (white iron) to withstand the abrasive wear of
slurries, or the pump is lined with rubber for more round-edged slurries. Pumps often have replaceable
wear plates on one or both sides of the impeller.

Applications Used

Mining, minerals processing, transportation of slurries for processing, and dredging . Also pumps used in
slurry applications in coal fired power plants, steel mills, cement mills, etc.

Recommended Media (Fluid)

Very abrasive liquids of all types

Advantages

Ordinary pumps wouldn't withstand the abrasive wear that slurries cause on pump parts. Slurry pumps
are designed to handle abrasive slurries and give pumps the longest life possible.

Flow Rate Ranges

10- 30,000 gpm

Total Head (Pressure) Ranges

30 - 250 ft

HP Ranges

1 -2000 hp
 Method Statement – Sludge Pumping & Piping Design

4. Execution Plan:
Step 1: Determining Fluid Properties

Following properties / parameters required to execute the pump hydraulics and line sizing:

 Flow rate
 Density
 Specific heat
 Thermal conductivity
 Viscosity

Step 2: Line Sizing

Pipe lines are to be sized based on allowable limits of erosional velocity and pressure drops.

Step 3: Pump Sizing

Pumps are sized by calculation TDH and Power requirement

Step 4: Piping & Instrumentation Diagram

After the equipment’s and lines sizing Piping and Instrumentation diagram is prepared consisting of
necessary instrumentation and valves for the safe and easy operation of the system.

Step 5: Datasheets and Required Project documentaion

Followed by PID’s datasheets for equipment’s & instruments will be prepared for getting vendor offers
and procurement. All necessary documentation for the project will be provided as per agreed scope.

Step 6: Surge Analysis

Based on the criticality Surge analysis will be performed and the forces are used for pipe supports.

Step 7: Preparation of Fabrication Drawings

GA drawing and piping drawing will be prepared after completion of process design

5. Software’s / Design Tools

a. Pipenet Transient Module

b. AutoCAD.
c. MS office & Adobe PDF
 Method Statement – Sludge Pumping & Piping Design

6. Time Duration:

1. As per agreed scope process design will be completed in 60 days from the date of receipt of all
the inputs.

7. Technical Team Details

Team Member Activity CV

Pavan Kumar.Ch
Process Design
(Sr. Engineer – Process)

Alla Vijay Kumar

Process Design
(Sr. Engineer – Process)

Kiran Kumar
Piping / Mechanical Design
(Sr. Engineer – Mechanical)