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Cálculo Bombas
Cálculo Bombas
M
Joseph any aspiring chemical engineers Suction side Discharge side
Sarver, Blake enter industry after university
Finkenauer and study without sufficient practical PD
Y.A. Liu knowledge about how to prop-
Ps
Virginia Polytechnic erly size pumps. A number of recent articles
Institute and State provide useful guidelines for sizing and se-
University lecting pumps, but these articles focus on D
S
certain specific aspects of proper pump siz-
ing, while leaving out others [1–4]. Chemical
IN BRIEF engineering literature does not fully cover
PUMP SIZING OVERVIEW other essential aspects of pump sizing and
selection — including the viscosity correc-
CALCULATING FRICTION tion, power consumption, commercial avail-
LOSSES Vs, hs,h, hs Vd, Hd,f, hd
ability and lifecycle cost analysis.
NET POSITIVE SUCTION In industrial operations, pumping alone FIGURE 1. The following components are needed to calculate
HEAD can account for between 25 and 50% of the total dynamic head: suction and discharge elevation; fluid ve-
locity; friction loss and dynamic head; and tank pressure
VISCOSITY AND PUMP
total energy usage of the process, depend-
SIZING ing on the application [5]. The initial purchase Pump sizing overview
price of a pump is only a small fraction of The concept of a pumping system is rather
PUMP CURVES the total lifecycle cost. There are situations simple. The suction side refers to everything
CALCULATING POWER in which purchasing a less expensive pump before the pump, while the discharge side
AND EFFICIENCY actually leads to greater energy-usage costs. refers to everything after the pump. Figure
This results in a higher lifecycle cost (see Ex- 1 illustrates a simplified pumping system. A
SUCTION SPECIFIC
SPEED
ample 1, p. 36). key parameter in characterizing a pump is
Without a proper understanding of the the total dynamic head (TDH), which is the
AUTOMATED EXCEL pump selection process, engineers can- difference between the dynamic pressure
SPREADSHEET not effectively make both economic and of the discharge side and the suction side.
practical decisions. This article aims to fill The dynamic pressure represents the energy
in some of the gaps in understanding and required to do the following: (1) to raise the
provide a straightforward method for pump liquid level from the suction tank to the dis-
sizing and selection. Along with this article, charge tank; (2) to provide liquid velocity in-
we have created a useful Microsoft Excel side both suction and discharge piping; (3)
spreadsheet to assist with centrifugal pump to overcome frictional losses in both suction
sizing. The automated Excel spreadsheet and discharge piping; and (4) to pump the
assists in calculating the key parameters for liquid against the pressure difference be-
pump sizing and selection. Since the major- tween the suction and discharge tanks.
ity of the pumps used in the chemical pro- Six steps to pump sizing. In order to size a
cess industries (CPI) are centrifugal pumps, pump, engineers need to estimate the tem-
this article focuses on that equipment cat- perature, density, viscosity and vapor pres-
egory, rather than the other general classes sure of the fluid being pumped. Pump sizing
of pumps, such as rotary and positive dis- can be accomplished in six steps, as follows:
placement pumps. 1. Find the total dynamic head, which is a
34 CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM JANUARY 2018
A G C B D E cial pump is readily available (see
ft gal/min
700 10,000 CS CHP section on suction-specific speed
Co 10,000 1.80
1.00 later in this article)
1.50
5,000 4,000 5. Check for potentially suitable
400 CH
0 2,000 1.40 pumps using a composite per-
1,000 formance curve and an individual
2,000 1.30
200 0.95 pump performance curve
F 400
1,000
6. Compare the energy consumption
200
1.20
and lifecycle cost of operating the
0.90 100
100 0.05
selected pumps
500
40 1.15
20 Calculating friction losses
0.80 200 10 1.10 Pumps must overcome the frictional
0.10
40 6 losses of the fluid in order for the
0.70 100 1.05 fluid to flow in the suction and dis-
0.15 charge lines. These frictional losses
0.60
20 0.18 50 depend on pipe roughness, valves,
15 30
fittings, pipe contractions, enlarge-
1.00
ments, pipe length, flowrate and liq-
FIGURE 2. Shown here is a viscosity correction chart. The red dashed line corresponds to Example 2 on
p. 40
uid viscosity.
To calculate the frictional head
function of the four key compo- viscosity of other process fluids losses, in feet of liquid being
nents of a pumping system, such can differ dramatically pumped, on the suction (hs,f) and
as the one shown in Figure 1 3. Calculate the net positive suction discharge (hd,f) side of the pump,
2. Correct for the viscosity of the head (NPSH) to select a pump that Equation (1) can be used. The same
fluid being pumped, since pump will not undergo cavitation equation can be applied to calculate
charts and data are given for 4. Check the value of suction-spe- the frictional losses of the discharge
water with a viscosity of 1 cP. The cific speed to see if a commer- side, but with the appropriate values
•Workson3phase,fixedorvariable 18
frequency,DCandsinglephasepower 16
POWER
SENSOR
14
SENSITIVE
•10timesmoresensitivethan 12
0
BATCH 1 BATCH 2 BATCH 3
T
he following is a pump sizing problem to illustrate the calculations in this article. You are told to purchase a pump for your manufacturing
facility that will carry water to the top of a tower at your facility. The pump is a centrifugal pump that will need to pump 800 gal/min when
in normal operation. Assume BHP is 32 and 16 horsepower for the 3,500-rpm and 2,850-rpm pumps, respectively, for all pump choices
in the composite curve. The pump operates for 8,000 h/yr. Assume all of the pumps are viable for your required flowrate. The suction-side pipe
and discharge-side pipe diameters are 4 and 3 in., respectively. The suction tank elevation (S) is 12 ft, and the discharge tank elevation (D) is
150 ft. Pressure on the suction side is atmospheric pressure (1 atm = 14.696 psi) and the pressure on the discharge side is 1.1 atm. Assume
that both hd,f and hs,f are roughly 10 ft.
Based on a five-year life, the objective of the problem is to calculate the lifecycle cost to operate each pump (that is, the costs of installa-
tion, maintenance and electricity, which is $0.18/kW), and to choose the pump with the lowest lifecycle cost (depreciation is assumed to be
negligible for this example). The pump curves in Figure 3 illustrate the following pump options to choose.
Solution:
Convert volumetric flow to velocity:
Continued on page 37
correlating to the discharge side of inches, v is the average fluid veloc- the frictional losses due to valves, fit-
the pump. ity in ft/s, g is the acceleration due tings, pipe contractions and enlarge-
to gravity in ft/s2, ni is the i-th valve, ments. We have provided the values
fitting, pipe contraction and enlarge- for the typical resistance coefficients
ment and so on, and ki is the resis- and pipe surface roughness from
(1) tance coefficient. the chemical engineering literature in
The first term in Equation (1) rep- the Excel spreadsheet discussed in
In the equation, fD is the Darcy resents the frictional losses from the this article.
friction factor, L is the pipe length in fluid flowing through a straight piece A control valve follows the widely
feet, I.D. is the inner pipe diameter in of pipe. The second term represents accepted heuristic of having a fric-
36 CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM JANUARY 2018
PUMP SIZING AND SELECTION EXAMPLE 1 (CONTINUED)
From looking at the TDH and Figure 3, the choice is between Option 1 and Option 2. Notice that most of the TDH comes from the signifi-
cant elevation difference between the suction and discharge side. Now that two pumps are feasible from the perspective of TDH require-
ments, you can compare the economics. At first glance, it is tempting to choose Option 1, since the initial investment is significantly lower.
Although Option 2 has a higher initial cost, the lifetime cost over five years is dramatically lower. The problem shows that, in selecting a
pump, the costs associated with power consumption and maintenance are critical pieces of information for making an informed decision.
tion head loss of 25% of the total less ratio of surface roughness to
calculated friction head loss on the pipe inner diameter. The equation for (6)
suction or discharge line where the the Reynolds number of a circular
valve is located [4]. An illustration of pipe appears in Equation 3. (7)
this solution can be observed in Ex- The total dynamic head depends
ample 2 on page 40. We also imple- (3) on the elevation difference between
ment the same heuristic within the the discharge tank and suction tank
Excel spreadsheet. In the equation, µ is the fluid vis- (Figure 1). In Equations (5) and (6),
The Darcy friction factor fD can cosity, is the fluid density, D is the P is the pressure of the suction or
be calculated using the Churchill pipe inner diameter, and v is the av- discharge side converted to units of
equation, Equation (2), which is ap- erage fluid velocity. length using the specific gravity of
plicable for all values of Reynolds A useful heuristic is to add a 15% the fluid as in Equation (7). The TDH
number (Re). safety factor to reduce the chance of represents the difference between
underestimating the calculated fric- Equations (5) and (6), in which users
tional head losses. Sample calcula- actually add together the velocity
tions using these equations appear in head and the frictional head loss
the examples within this article. for both the suction and discharge
sides of the pump.
Calculating total dynamic head
To find the total dynamic head, the Net positive suction head
difference between the discharge ve- NPSH is used in the determination
locity head (hD) and the suction veloc- of whether the liquid on the suction
ity head (hs) needs to be calculated. side of the selected pump will vapor-
ize at the pumping temperature, thus
(2) (4) causing cavitation and rendering the
pump inoperable. NPSH varies with
In the equation, Re is the Reynolds (5) impeller speed and flowrate.
number and /D is the dimension-
A
n additional pump selection problem is shown Example 2. For this example, consider a discharge line that is 50 ft schedule 40, 4-in.
diameter, with two gate valves, 12 elbows, 1 expander (2–4 in.), a control valve, and a branched tee. The velocity is 12.84 ft/s, Reynolds
number is 1,601, and the Darcy friction factor is 0.119. The elevation difference on the discharge side is 17 ft, the total dynamic suction
head is 50 ft, and the pressure on the discharge side is 14.696 psi. The objectives in this example are to accomplish the following: 1) Calculate
the discharge frictional head loss and total dynamic head; 2) Correct for viscosity of the fluid, which is 300 cP at 125°C; and 3) select an ap-
propriate pump from Figure 3; and 4) Ensure that cavitation is not an issue with the selected pump given the vapor pressure is 13.93 mm Hg
and specific gravity is 1.20.
Solution: For choosing the appropriate pump, see Figures 3 and 4. Notice on the pump composite curve, the 4 x 3 – 10 section is very
close to the 4 x 3-8G. Both pumps should be analyzed by performing a lifecycle cost analysis using the pump efficiencies from the individual
pump performance curves.
Our NPSHa is much greater than the NPSHr and thus should avoid cavitation under normal operating conditions.
cosity-corrected TDH and pumping would need to move vertically up on read the BHP accurately; so instead,
capacity. The y-axis of the graph is the composite curve and choose a we recommend calculating the BHP
the equivalent water TDH. The x-axis pump with a larger impeller size (4 × manually using the pump efficiency
of the graph is the equivalent water 3 – 10 versus 4 × 3 – 8G). It is very according to Equation (12) below.
volumetric flowrate. Figure 3 has important to always compare the
multiple shaded sections, with each lifecycle cost for the different pumps Power and efficiency
corresponding to a different-sized (see Example 1 on p. 36). Brake horsepower (BHP) is the ac-
pump. In the individual sections, the After looking at the pump com- tual horsepower delivered to the
pumps are specified by the suction posite curve and selecting poten- pump shaft. To find the BHP for a
pipe diameter, discharge pipe diam- tial pumps, the next step is to look viscous liquid (BHPvis), use Equa-
eter, and impeller size (4 × 3 – 8G at the individual pump performance tion (9), after calculating the break
for our selected pump in Example 2). curves to obtain the pump efficiency, horsepower for the equivalent water
Remember that the larger pipe diam- NPSHr, and impeller size. Figure 4 values (BHPw, TDHwater and Qwater)
eter is always the suction side. For is an example of an individual pump and efficiency (p,w) from the pump
this pump composite curve, there performance curve. The required curve using Equation (12).
are two x-axes for different impel- NPSH is located at the bottom of
ler speeds. Notice that the two red this figure, separate from the rest
points both correspond to 570 gal/ of the performance curve. Keep in (12)
min of flow and 110 ft of TDH for the mind that not all pump curves are the
different impeller speeds (2,850 and same and vary by manufacturer. In To determine the electricity cost
3,500 rpm). The point that corre- Figure 4, the blue curve is for an 8-in. for operating the pump, use Equa-
sponds to this TDH and flowrate may impeller diameter. The green curve tions (13), (14) and (15). Equation
not be the pump that is ultimately is for a pump efficiency of 64% and (13) converts the BHP of your pump
selected. For example, if the point the red curve is for 30 BHP. In most to the input power or electricity con-
is close to the boundary, engineers pump curves, engineers could not sumption. Determining the power
40 CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM JANUARY 2018
SPECIAL REPORT
Digitalization
in the Chemical
Process Industries
This special report contains recent news articles (2017) from Chemical
Engineering magazine that give a timely and informative overview of digitalization
as well as a number of articles (2016) on related cybersecurity issues.
Articles include:
(16)