Pumps and Hydraulic Check PDF

PUMPS
AND
HYDRAULIC CHECK

CONTENT
1. Role Pumps Play in a Plant

2. Types of Pumps and Their Functions
3. Characteristic Curves
4. Malfunctions
5. Hydraulic Calculation
5.1 Overview
5.2 An Example
1
1. Role Pumps Play in a Plant
Human Plant
Heart .......................................Pump
Blood ......................................Water, Reactants
Blood Vessel...........................Pipes
Organ ......................................Equipment
(Muscles, Liver) .................(Filters, Heat exchangers)
2
2. Types of Pumps and Their Functions
Reciprocating
Positive Displacement Pump
Rotary Pump
Pump
Impeller
Centrifugal
Turbine
3
3. Characteristic Curves
Constant rpm
PUMP
SYSTEM
9
4. Malfunctions
A Water Hammer
B Cavitation
C Vibration
D Erosion
10
5. Hydraulic Calculation
5.1 Overview
11
Hydraulic Calculation
Objectives:
1 Pump Calculation
2 Control Valve P Calculation
3 Pipe Size Calculation
4 Instrument Addition/Elimination
5 NPSHA Calculation
6 Pump Ty6pe Determination
Suction
Reference Liquid Level Elevation in Pump Suction Drum
12
NPSHA (Net Positive Suction Head Available)
NPSHA = (Psv + Pa V p Pf ) + (H sv H p )
10
S .P. Gr.
Psv Suction vessel pressure, kg/cm2G

Pa Atmospheric pressure, kg/cm2 (General1.03 kg/cm2)
Vp True vapor pressure of liquid at pumping temperature, kg/cm2A
Pf Friction losses in pipe and fittings between suction vessel and pump
suction flange, kg/cm2
Hsv Elevation of fluid level in suction vessel during pumping operation, m
Hp Elevation of centerline of pump suction flange, m
NPSHR (Net Positive Suction Head Required)
NPSHA NPSHR
SPSHA NPSHR
VaporizationCavitation
NPSHA NPSHR
A. How to increase pumps NPSHA

(1) Raise the liquid level
(2) Lower the pump
(3) Reduce the line friction loss
(4) Use a booster pump
(5) Subcool the liquid
B. How to lower pumps NPSHR

(6) Use slower speeds
(7) Use a double suction impeller
(8) Use a larger impeller sys area
(9) Use an over-sized pump
(10) Use an inducer
(11) Several small pumps in parallel
13
TDH (Total Differential Head)
TDH = (Pdv Psv + Pfp + Pfs ) + (H dv H sv )

10
S .P. Gr.
Pdv Discharge vessel pressure, kg/cm2G

Psv Suction vessel pressure, kg/cm2
Pfd Friction losses in pipe and fittings between discharge vessel and pump
discharge flange, kg/cm2
Pfs Friction losses in pipe and fittings between suction vessel and pump
suction flange, kg/cm2
Hdv Elevation of fluid level in discharge vessel during pumping operation, m
Hsv Elevation of fluid level in suction vessel during pumping operating, m
Shut-off pressure
Min. Flow Bypass:

1. Pump Shut-off Full Close
2. Normal Flow Pump
Pump Min. Flow

1. Control Valve
2. ARVAuto Recirculation Valve
3. R.O.
25% ~ 75% Normal Flow Pump

14
Line Sizing
(1) Liquid
(i) Equation: Darcy Equation: See Attch. 3, 4, 5, 6

fL Q 2
P = 0.000216
d5
(ii) Sizing Criteria: See Table 1, 2
(2) Vapor or Gas
15
(i) Equation:
fL Q 2
c Darcy Equation: P = 0.000216
d5
d Isothemal Equation:
144 g A 2 (P1)2 (P 2 )2
W=
L P1 P1

V 1 f + 2 log e
D P2
(ii) Sizing Criteria: See Table 3
(3) Liquid/Vapor (Two Phase)
(i) Flow Pattern See Attach. 1, 2

(ii) Method
c Duller
d Martinetlt
(iii) Sizing Criteria: See Table 3
16
17
18
19
20
21
22
23
24
THIS DO CUMENT CONTAI NS CTCI CORPORATION CONFIDENTIAL I NFORMATION OF A PROPRIETARY NATURE. THIS INFORMATION MUST NOT BE CO PIED OR DI SCLOSED IN WHOLE OR IN
PART TO OUT SIDE PARTIES NOR USED FOR OTHER THAN THE PURPOSE FOR WHICH PRO VIDED WITHOUT PERMISSION OF MANAG EMENT.
GN-502 84.10
REV.
DESCRIPTION
BY
CHK.
MGR
APPR. DATE PAGE

PROJ.
CLIENT

1 OF 40
PROJECT NO.
CERTIFIED
DATE
DATE
DGS-07.10
CTCI CORPORATION
. (Title)
. (Fluid Characteristic)
. (Capacity)

. (Suction Calculation)
. NPSHa NPSHr
. (Discharge Pressure Calculation)
. / (Net Diff. Pressure/Head)
. (Hydraulic Horsepower)
. (Estimated Shutoff Pressure)
-1.
-2. (Line Sizing Criteria)
-3. NPSHa Safety Margin
-4. Pump Data Sheets
1. Pump Calculation Sheet (KM-565)
2.
3.
4.
5.
6. CPC Net Diff. Pressure Safety Factors
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6.
5.
4.
3.
2.
1.
CTCI CORPORATION
NPSHr

Suction
Minimum Flow Manintained By ARV
Minimum Flow Manintained By Restriction Orifice

Minimum Flow Manintained By Low Flow Control Valve

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(Pump Data Sheet)

Spool Isometric Drawing

(Schedule)

KM-565 ( 1)


EPCCPC Verify

(a) Client CPCTCPCKTSMC
(b) System No.5 TPA Sour

Water System
(c) Basic of Calculation SOREORCase 1 Case 2

(d) Project No. 89E666
(e) Service Bottom Feed Pumps
(f) Pump No. P-6101A/B
(g) Pump Type. Centrifugal RotaryMetering

Reciprocating
(h) Sheet No. Pump No. 1 of 11 of 2
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1. Pump Calculation Sheet (KM-565)
5 OF 40
REV.
DATE
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Check
(a) Name Arun CondensateWash Water Sour Water

No.6 Fuel Oil Diesel
(b) Pumping Temp. (PT)

Max./Nor./Min.

(c) Vapor Pressure(kg/cm2A)

True Vapor Pressure Reid Vapor Pressure
(RVP) RVP True Vapor Pressure API
Technical Data Chapter 5[1]
(d) Specific Gravity Pumping

Temp. Sp. gr
Sp. gr.
(e) Viscosity Pumping Temp.

(f) Non-Newtonian Fluid Properties

[2,3]
GelsSlurrysPaper stock
(g) Special Requirements
(1) (High Pour)

BPA TarSulfurHigh Pour Crude Oil

(2)
Sour
waterAmineNaOH
(3) (wt%)

Steam Cracker Quench System (Primary Fractionator Bottom)
Coker Unit Scrubber Bottom
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Catalyst Particle in Catalytic Cracking Unit
(4)
Terminal Pressure
Path
% CAPACITY OVER DESIGN =

DESIGN FLOW RATE - NORMAL FLOW RATE

100%
NORMAL FLOW RATE
Design Flow (Max.) Pump Data Sheet Rated FlowCapacity
Overdesign
PM139-5
1. The rated flow rate of centrifugal pumps are generally designed for the
following:
Feed and general pumps 110%
Reboiler 120%
Pumparound 120%
Reflux 125%
BFW pump 125%
Byproducts consider variations
2. Design capacities for reciprocating or rotary pumps will depend on the

service.
3. Since metering pumps generally have a 10 to 1 range on flowrates, the

normally required capacity is set in the middle of this range.
Normal Flow Rate Process Flow Diagram Design case

Stream Table Line List Flow Rate Velocity/Pressure Drop

(Discontinuous) % Over Design

(Intermittent)
MIN. Flow Bypass (1)

Shutoff Full Close (2)
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Nor. Flow Capacity

Min. Flow
Pump Capacity (Min. Flow)

( 1)ARV ( 2)( 3)
[5]Min Flow
25% - 75% Normal Flow [6]
( DGS-07.08)( 3)
Data Sheet Nor. Capacity Normal Flow + Min. Flow Rated
Capacity Rated Flow + Min. Flow

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KM-565 Pump Calculation Sheet Line 1 Line 13
LINE 1ELEVATION OF MIN. LIQUID LEVEL
(Elevation) 0

(Slop)
Suction Vessel
4A4I
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LINE 2ELEVATIONS OF PUMP IMPELLER CENTERLINE 4

2
(H)
CENTERLINE OF
IMPELLER
TOP OF
(H) FOUNDATION

[10]
2.
GPM M3/HR IMPELLER CENTERLINE
ELEVATIONS (H)
UP TO 200 UP TO 45 2'- 10" 850 MM
201-1000 46-227 3'- 6" 1050 MM
1001-10000 228-2270 5'- 1" 1550 MM
10001-20000 2271-4540 6'- 1" 1850 MM
LINE 3: MINIMUM STATIC HEAD
LINE 3 = LINE 1 LINE 2, m
LINE 4 MINIMUM STATIC PRESSURE
LINE 3 (Static Head)
StaticHead ( m) Sp . gr .
= Static Pressure, ( kg / cm2 )
10
Sp.gr. Normal Pumping Temperature
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LINE 5 PRESSURE AT LIQUID LEVEL
MIN. Normal Pumping Temperature
LINE 6 TOTAL PRESSURE CREDITS

LINE 6 = LINE 4 + LINE 5

LINE 7TOTAL SUCTION LINE EQUIVALENT LENGTH[7]
Suction Side Piping Equivalent Length

(Preliminary)
(a) Plot Plan Piping Routing

= +

(b) Plot plan (Lh), Nozzle Suction

Nozzle Lv(Le)
Suction Line Spool Isometric Drawing

-1 [12]
LINE 8 LINE LOSSES
Suction pipe Schedule No.

kg/cm2/100m Line Sizing
-2 (Line sizing Criteria)

LINE 9TOTAL SUCTION LINE LOSSES
kg/cm2
LINE 10MISCELLANEOUS LOSSES
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Line Acceleration Loss
(Dampener) (Ha)
Ha 3
5 Ha Ha

Acceleration Losses Data sheet "Acceleration

Loss should be Considered By Vendor". Suction side Line Size
True pipe Length Data sheet Vendor

Acceleration Losses.
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LINE 11SUCTION EQUIPMENT LOSSES
4 Suction Equipment Losses
Equipment Data sheet NPSHa
LINE 12TOTAL SUCTION LOSSES

= LINE 9 + LINE 10 + LINE 11, kg/cm2
LINE 13 PUMP SUCTION PRESSURE
= LINE 6 - LINE 12, kg/cm2G
Pump Suction PRESSURE PRESSURE

DROP DROP
(PSI) (KG/Cm2)
PUMP SUCTION STRAINER
TEMPORARY STRAINER 0.0 0.0
PERMANENT STRAINER 0.5 0.035
BASKET STRAINER 0.7 0.05
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NPSHa NPSHr
NPSHa NPSHr
NPSHa NPSHr
(Vaporization)(Cavitation)
NPSHa NPSHr[11]
A. How to increase pump's NPSHa
(1) Raise the liquid level

(2) Lower the pump
(3) Reduce the line friction loss, i.e enlarge the line size
(4) Use a booster pump
(5) Subcool the liquid
B. How to lower pump's NPSHr
(6) Use slower speeds
(7) Use a double suction impeller
(8) Use a larger impeller eye area
(9) Use an over-sized pump
(10) Use an inducer
(11) Several smaller pumps in parallel
LINE 14 PUMP SUCTION PRESSURE
LINE 13 1.033 kg/cm2A
LINE 15 VAPOR PRESSURE
Max. Pumping Temperature kg/cm2A
LINE 16AVAILABLE PRESSURE
LINE 16 = LINE 14 - LINE 15, Kg/cm2
LINE 17 NPSHa
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NPSHa "m"
Available Pressure ( kg / cm2 ) 10

NPSHa =
Sp. gr .
NPSHr 5-15 ft(1.6 -4.7 m) NPSHa

Critical Flow ( Surface
Condenser Bottom Pump) NPSHa

NPSH
NPSHa (Top of Foundation At Pump Suct.)

Line 2Line 17Line 28 Pump Data
Sheet NPSHa NPSHr
Pump Suction Nozzle Centerline Technique
Evaluation NPSHr review Critical Flow Pump

Pump Data Sheet NPSHa
-3
NPSH Safety Margins
Margin (=NPSHa-NPSHr) NPSHa

Data Sheet (Safety Margins - Margin)
[ 1] BFW Pump NPSHa = 20 ft NPSHa

- NPSHr = 3 ft 3BFW NPSH Safety Margins 7 ft Pump
Data Sheet NPSHa 20-(7-3)=16ft
[ 2] BFW Pump NPSHa = 20 ft NPSHa

- NPSHr = 3 ft 3BFW NPSH Safety Margins 7 ft Pump
Data Sheet NPSHa 20-(7-0)=13ft
[ 3] CW Pump NPSHa = 20 ft NPSHa -

NPSHr = 3 ft 3CW NPSH Safety Margins 2 ft Pump Data
Sheet NPSHa 20-(2-3)=20ft (2-3) 0
[ 4] CW Pump NPSHa = 20 ft NPSHa -

NPSHr = 3 ft 3CW NPSH Safety Margins 2 ft Pump Data
Sheet NPSHa 20-(2-0)=18ft
NPSH Margin
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LINE 18 NPSHr

6[7] NPSHr
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LINE 19 FLOW RATE
Normal Flow Rate
LINE 20 LINE LOSSES
1. (kg/cm2/100m)
(Terminal)

(Section)
Line Sizing
-2
2.
Discharge Side Piping equivalent Length

(Preliminary)
(a) Plot Plan Piping Routing

= +

(b) Plot Plan ( )( )

( )( )
= 3+ 2 ( 10" )
= 5+ 2 ( 10" )
Discharge Side Spool Isometric
Drawing -1
[12]
Le
3. (Section)= x , kg / cm2
100
LINE 21TOTAL LINE LOSSES
(Section)Line Losses
LINE 22EQUIPMENT LOSSES
Equipment Data Sheet Allowable
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Pressure Drop Instrument Mixer

5
EQUIPMENT PRESSURE DROP PRESSURE DROP
(PSI) (KG/CM2)

ROTARY & TURBINE 3-6 (AT MAX. FLOW) 0.25-0.5

FLOW ORIFICE 2 0.15
FLOW SUMMETER(FQI) 1.0
STATIC MIXER 5-10 0.35-0.7
ORIFICE MIXER 1-5 (EACH) 0.1-0.35
MIXING VALVE 5-20 0.35-1.4
WIREMESH DEMISTER 1" H2O 0.003
STRAINER 7-14 0.5-1.0
ARV 5-5.5 0.35-0.4
LINE 23 ORIFICE LOSSES
(Range) 50012502500 5000 mm

(Max. Pressure Drop)
(Vaporization)
0.25 kg/
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LINE 24TOTAL VARIABLE PRESSURE DROP
LINE 21,22,23 Total Variable Pressure Drop

Max. Flow 2
Pmax . = ( ) PNor .

Nor. Flow
Min. Flow 2
Pmin . = ( ) PNor .
Nor. Flow
LINE 25 CONTROL DEVICE LOSSES

Normal Flow Pressure Drop

1. For pumped circuits, normal Control Valve P shall be
A. At least 33% of the friction P(not including control valve P)
B. At least 7% of the pump differential head
C. A minimum of 15 psi (1.0 kg/cm2)
2. The control valve normal flow will be the material balance flow (max.
normal)
LINE 26 OTHER LOSSES
LINE 27 TERMINAL PRESSURE
Process Design Case Max Normal Operating Pressure

(kg/cm2G) EOR SOR
code Terminal Pressure Design Pressure
(PSV) Termal Pressure

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LINE 28 STATIC HEAD
STATIC HEAD
Static Head =
H 1 1 H H
+ 2 2 + 3 3 , kg/cm2
10 10 10

1. ( Heater Cooler)
H 1 1
kg/cm2
10
2. ( Heater Cooler)
H 2 2
kg/cm2
10
H 3 3
3. kg/cm2
10

Controlling Poing
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LINE 29 DISCHARGE PRESSURE

LINE 29LINE 24+25+26+27+28, kg/cm2G
1 = 2 = 3 ,
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Static Head Recovery
09/13/11
LINE 30 DESIGN DISCHARGE PRESSURE
Rated Flow LINE 32 Net Diff. Pressure

Safety Factors Pump Data sheet
LINE 30 = (LINE 32) x SAFETY FACTORS + (LINE 31)

LINE 31DESIGN SUCTION PRESSURE
LINE 13 DATA
LINE 32 NET DIFFERENTIAL PRESSURE
Normal Flow Case
LINE 32 = LINE 30 - LINE 31
Safety factors (Priority)
(1)
(2) EPC Safety Factor
(3) Safety Factor
(4) Factors Data Sheet Safety Factors

Line 30
(5) 6 Safety Factors CPC DS 6.02
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6. CPC SAFETY FACTORS
NET DIFFERENTIAL PRESSURE SAFETY
FACOTORS

(% OF HEAD)
1.0 kg/cm2 and below 125
Greater than 1.0 kg/cm2 to 2.0 kg/cm2 120
Greater than 2.0 kg/cm2 to 3.0 kg.cm2 115
Greater than 3.0 kg/cm2 to 10.0 kg.cm2 110
Greater than 10.0 kg/cm2 105
LINE 33 DIFFERENTIAL HEAD
LINE 32 (m)
LINE 32 x 10
LINE 33 =
SP . gr .
Sp.gr. SP.gr.
Sp.gr () Sp.gr

Sp.gr. Sp.gr. Pump Driver

Pump Data Sheet Data Sheet
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Normal HP =
CTCI CORPORATION
Design H p =
Sheet Rated Flow

36.7
36 .7
LINE 32 x Normal Flow
, kw
LINE 32 x Rated Flow

LINE 34 HYDRAULIC HORSEPOWER
, kw

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Rated Flow % Over Design Design Flow Pump Data
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Shutoff
(Lv) (Pv) Min. Flow
Shutoff Pressure.
LINE 35 MAX. SUCTION PRESSURE
H x Sp.gr.
Max.Suc.Press. = Suction PSV set press. + , kg / cm 2 G
10

1. Max. Suc. Pressure LINE LIST Variation
2. Max. Suc. Pressure Pump Data Sheet
LINE 36 SHUTOFF DIFFERENTIAL, HQ=0
(Motor) (Turbine)
( Q = 0
)
15% pressure rise due to pump characteristics
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5% pressure rise allowance for manufacturer' tolerance
5% speed allowance for turbine control (governor) tolerance
6% speed allowance for reduced load
Assume normal differential = dP (Data From LINE 32)
Since (Pressure) is proportional to (speed) squared
1.5 dP

SHUT OFF DIFFERENTIAL (TURBINE DRIVER) =

2 2
15 105 105 106 150
(( dP + dP ) x ) = dP; kg / cm 2
100 100 100 100 100
(Take 145)
1.2 dP
SHUT OFF Differential (Motor driver) =
15 105 120
( dP + dP ) x = dP; kg/cm 2
100 100 100
Turbine LINE 36 = 1.45 x LINE 32
Motor LINE 36 = 1.2 x LINE 32
LINE 37 SHUTOFF PRESSURE [8]
[7]
SHUTOFF PRESSURE, HQ=0
= Max. Suc. Press + Nor.diff. Pressure
= Normal Suc. Press + (1.2/1.45) Nor diff. press.
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CPC DS-6.02 3.4.6 3.4.7 (Positive

displacement)
The relief valve for rotary pumps, reciprocating-steam pumps and

reciprocating-power pumps shall be preferably of flanged steel construction, of
closed top, capable of bypassing all fluid to the suction.
Relief valve shall be set to operate not more than the maximum allowable
working pressure but no less than 110 percent of the rated discharge pressure

or the rated pressure plus 1.7 kg/cm2 (25 psi), whichever is greater.
PSV Set Pressure
Set Pressure
of Relief Valve
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1. API Technical Data Book-Petroleum Refining, Chapter 5 (1978)
2. A.A. Sultan, "Sizing pipe for Non-Newtonian Flow", Chemical Engineering,

DEC.19, P.140-146 (1988)
3. Hydraulic Insitute Standards for Centrifugal, Rotary & Reciprocating

Pumps, 14th, P.111-114(1983).
4. PM139-5

5. Henry J. Sandler, Practical Process Engineering: A working Approach to

Plant Design, McGraw-Hill P.431-432(1987)
6. Irving Taylor, "Pump Bypasses Now More Important", Chemical

Engineering, May 11, P.53-57 (1987)
7. CPCK No.2 Xylene Project, 90E794 JGC
8. CPC No.5/No.6 Reforming Project, 89E666 ITB EXIBIT 4 Page 19.
9. PM-048 (3/5)
10. PM-046 (3/3)
11. Igor J. Karassik, "Centrifugal Pumps and System Hydraulics", Chemical

Engineering, Oct. (1982)
12. Design Manual DGS-03.01
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-2 (Line Sizing Criteria)
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-3REFERENCE SAFETY MARGIN OF NPSHa
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-4
See EGS07
PUMP DATA SHEETS

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PUMPS

1. Role Pumps Play in a Plant

Blood ......................................Water, Reactants

(Muscles, Liver) .................(Filters, Heat exchangers)

Psv Suction vessel pressure, kg/cm2G

NPSHR (Net Positive Suction Head Required)

A. How to increase pumps NPSHA

B. How to lower pumps NPSHR

TDH = (Pdv Psv + Pfp + Pfs ) + (H dv H sv )

Pdv Discharge vessel pressure, kg/cm2G

Min. Flow Bypass:

25% ~ 75% Normal Flow Pump

(i) Equation: Darcy Equation: See Attch. 3, 4, 5, 6

(2) Vapor or Gas

(ii) Sizing Criteria: See Table 3

(3) Liquid/Vapor (Two Phase)

(i) Flow Pattern See Attach. 1, 2

APPR. DATE PAGE

. (Discharge Pressure Calculation)

. / (Net Diff. Pressure/Head)

. (Estimated Shutoff Pressure)

-2. (Line Sizing Criteria)

-3. NPSHa Safety Margin

-4. Pump Data Sheets

1. Pump Calculation Sheet (KM-565)

6. CPC Net Diff. Pressure Safety Factors

Minimum Flow Manintained By Restriction Orifice

(Pump Data Sheet)

(a) Client CPCTCPCKTSMC

(b) System No.5 TPA Sour

(c) Basic of Calculation SOREORCase 1 Case 2

(d) Project No. 89E666

(e) Service Bottom Feed Pumps

(f) Pump No. P-6101A/B

(g) Pump Type. Centrifugal RotaryMetering

(h) Sheet No. Pump No. 1 of 11 of 2

(a) Name Arun CondensateWash Water Sour Water

(b) Pumping Temp. (PT)

(c) Vapor Pressure(kg/cm2A)

(d) Specific Gravity Pumping

(e) Viscosity Pumping Temp.

(f) Non-Newtonian Fluid Properties

(g) Special Requirements

(1) (High Pour)

Steam Cracker Quench System (Primary Fractionator Bottom)

Coker Unit Scrubber Bottom

Catalyst Particle in Catalytic Cracking Unit

% CAPACITY OVER DESIGN =

DESIGN FLOW RATE - NORMAL FLOW RATE

Feed and general pumps 110%

BFW pump 125%

Byproducts consider variations

2. Design capacities for reciprocating or rotary pumps will depend on the

3. Since metering pumps generally have a 10 to 1 range on flowrates, the

Normal Flow Rate Process Flow Diagram Design case

(Discontinuous) % Over Design

MIN. Flow Bypass (1)

Nor. Flow Capacity