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Problem Statement:
Design of a pump system for supplying seawater to Taronga Zoo to fulfil daily requirements

Given Information and Requirements:
Design Criteria-seawater supply
Pool Capacity Filling frequency
Time to
fill (hrs)
Flow rate
(l/s)
Pump
Requirements
MI 1 234100 1 to 3 months 6 10.8 Required
MI 2 647000 1 to 3 months 13 13.8 Required
MI 3 83235 Daily at a certain time Required
MI 4 40000 Continuous 3 3.7 Required
MI 5 12000 Continuous 3 1.1 Required
MI 6 12000 Continuous 3 1.1 Required
Balance Tank Make up Intermittent Required

Requirements:
1. Head loss calculation
2. System curve of the pump
3. Choosing appropriate pipe and pump material for seawater
4. Finding operating point
Calculation Method:
Step 1: Optimizing the flow rate
MI4, MI5, MI6 pools require continuous filling with total flow rate (1.1+1.1+3.7=) 5.9 l/s for 34
hours.
M2 requires 13.8 l/s for 13 hours which is maximum requirement among all other pools.
Therefore the worst case scenario (which requires maximum flow rate at a time) would be a
flow rate of (13.8+5.9 =) 19.7 l/s
Therefore Q
req
=19.7 l/s = 0.0197 m
3
/s
Step 2: Calculate total head loss
Applying Bernoullis equation at seawater level and discharge point considering all losses
and solving for pump head concludes following equation.

)
Where, various system specifications are:
z
2
= delivery height = 20.8m, z
1
=suction height = -1m, therefore (z
2
-z
1)
= 21.8m
L = total length of pipeline, = 4.2m + 55.2m + 175m = 234.4m
Components of the system (considered from the sketch):
3 fully open and 1 half open valves (case 1, when maximum flow is not happening) or 4 fully
open valves (case 2, when maximum flow is happening) with two bends.
From loss coefficient table for various transitions and fittings we get,
For fully opened valve, K=0.2
For half opened valve, K=5.6
For bends, K=1.1
Case 1:

)
Case 2:

)

It is obvious that case 1 is the worst case as it results higher head. In order to account all
situations we will use first case as our governing equation. Converting velocity into discharge
to get a relationship between head and discharge in order to develop system curve for the
pump reveals;

) (1)
At this stage we have to work out for pipe size and materials in order to get D and f
Step 3: Choosing pipe size and material
Since the seawater is corrosive due to salty nature, it is important to choose a pipe with
anticorrosive property. Copper is one of the best anticorrosive material which suits excellent
for seawater pumping. Therefore copper pipe is chosen for this system.
Regarding the pipe size specification, we have to choose a size from nominal pipe size
(NPS). Let we take NPS 4, Schedule 40 for which specifications are as follows
Outer dia, OD = 11.43cm (4.5 in)
Wall thickness, t = 0.602 cm (0.237in)
Therefore Inner dia, ID = 11.43-0.602 cm = 10.23 cm
We will use inner dia of the pipe for all calculations.

Step 4: Calculate flow type
Reynolds number,

,
Where V = Maximum required velocity of water inside the pipe = Q
req
/A =

= 2.4 m/s
D = Diameter of pipe = 0.1023 m
= kinematic viscosity of seawater
Let assume the temperature of seawater is 20, and salinity is 35 g/kg; So at 20,

So

= 2.34e5
Therefore the flow is turbulent
Step 5: Calculate Friction factor
In turbulent regime the friction factor can be calculated with the following formula

)]

For Copper K
s
= 0.0015 mm = 1.5e-6 m
Plugging all values gives, f = 0.01522
With these values now heading back to step 1 equation 1

Step 6: plotting system curve
For difference Q, calculated
head

Q
(m3/s) hp (m)
0.001 21.82631
0.006 22.74714
0.011 24.98345
0.016 28.53524
0.021 33.40251
0.026 39.58525
0.031 47.08347
0.036 55.89716


Step 7: Selecting appropriate industrially manufactured pump:
Based on our requirement and study from different available pump from the manufacturer,
we have selected the FHS-50-200 (2900 rpm) model centrifugal pump from LAWARA Pump
Company (xylem brand).
0
10
20
30
40
50
60
0 0.005 0.01 0.015 0.02 0.025 0.03 0.035 0.04
P
u
m
p

h
e
a
d
,

h
p

(
m
)

flow rate, Q (m3/s)
System curve

Step 8: Finding operating point
The pump performance curve is regenerated in excel by taking some of the points from the
actual curve and then plotted along with our system curve. The intersection of two curve
gives the operating point of the system

From the above graph we have found that the operating point is
Flow rate, Q = 72 m
3
/h and Pump head, h
p
= 33 m
0
10
20
30
40
50
60
0 20 40 60 80 100
P
u
m
p

h
e
a
d
,

h
p

(
m
)

flow rate, Q (m3/h)
Head vs Flow rate
Perform
ance
Curve
Conclusion and Final Remarks:
After all calculation procedure we have found that the system should operate in a flow rate
72 m
3
/h along with pump head 33m. From the economical point of view although the initial
cost might be high because of high price of copper, which we have selected for pipe lines,
but in long run, it will optimize the overall cost. Seawater is a corrosive material and forms
rust in pipe wall. This incurs fouling effect which in turn reduces the system efficiency by
increasing frictional drop. Copper is resistant to fouling and therefore the system will run for
longer period smoothly. Although the system does not requires the maximum flow rate all the
time according to specification of requirement, but still we have to design it considering
maximum flow rate and hence velocity so that it does not get stuck during maximum
requirement. In order to optimize we have used a half open gate valve in the pipe line to
control the flow rate in different situation. In order to draw the system curve a relationship
have been developed between head and flow rate considering all sorts of losses in the
system. This system curve is overlapped with the performance curve of selected pump to get
the operation point.