1|Page

2|Page

About Author

Mr. L.K. Singh is an NIT graduate having 14 years of

versatile experience in oil & gas (onshore/offshore),
refinery, petrochemical & chemical Technology
research & development, engineering design &
consultancy including commission in India & abroad.
While working in top companies in India & abroad,
He got a great insight into equipment design &
process design engineering special studies works. He
is professionally Charted Chemical Engineer from
IChemE, UK Council, London since 2014.

He has also published few technical papers on his

innovative design work. Now he is running his own
engineering design company. He is a CEO & founder
of his company Petrohorizon Oil & Gas Engineering.
He is providing Engineering Design Consultancy
Services to Oil & Gas & other hydrocarbon field
operating & producing companies. Authors also
provide internship & training to engineers to become
design professionals.
3|Page

Preface

This book is all about the fluid mechanics concept

and centrifugal pump design/sizing calculations. This
book will provide in-depth insight to engineers for
understanding fluid mechanics and performing pump
design calculations like the design professional
engineers. Fresher & undergraduate engineers will
get the practical concept to understand fluid flow/
fluid mechanics concept to solve any competitive
exams and academics subject problems. This is the
first edition and the first volume of the book & I have
tried to include all the required concept &
calculation with an example to make easily
understandable for the reader.

This book covers only compressible fluid. The

incompressible fluid is not included in this book
intentionally. Since, incompressible fluid involves
more thermodynamics than fluid mechanics. My
book volume II will cover incompressible fluid
concept with compressor and blower design.

Any valuable suggestion from the reader & design

professional will be valuable for us to make this book
next edition more accurate & useful.
4|Page

Introduction

This book starts with required unit conversion for

pump design/ sizing calculation. In this book, the
content is not divided into chapters. In spite of that,
step by step topic is listed in the Index. It is
mandatory for a reader to read this book stepwise to
understand fundamentals and concepts; required for
design calculations. If you read this book, sequence-
wise, step by step, you will be able to perform the
pump design calculation like a professional Process
Design Engineer and understand fluid mechanics in
depth.

In this book, I have included the manual calculation

for steady-state curves [when the pump is not
running] and dynamics curves [when the pump is
running], with the help of this book you can draw
each pump curve manually using excel.

Book provides clear understanding where process

design engineer usually get confused.

For engineering students, this book should be read

as reference book for advance fundamental
knowledge of subject and design useful for working
in real industry specially design field.
 5|Page

Index

 Unit conversion
 List all 43 topics
(1) Bernoulli’s Equation Application
(2) Centrifugal pump suction & Discharge piping size
calculations
(3) What is pump?
(4) Pump parts explanation
(5) How pump produce pressure?
(6) How to design pump? What are the design
parameters we need to calculate for pump sizing
calculation?
(7) What is NPSHA?
(8) What is NPSHR?
(9) How to calculate pump Impeller diameter?
(10)How to select pump impeller type?
(11)Pump impeller geometry
(12)Pump affinity laws
(13)Pump specific speed
(14)Pump suction & discharge piping or pump loop
schematic & PIDS
(15)Pump suction & discharge piping hydraulic
calculation
(16)Pump control valve pressure drop calculation
 6|Page

(17)Pump NPSHA calculation

(18)Pump discharge head calculation
(19)Pump differential head calculation
(20)Pump shut off pressure calculation
(21)Pump characteristic curves
(22)Pump performance curves
(23)Pump system resistance curve
(24)Pump operating points
(25)Pump power consumption calculation
(26)Pump operating & control philosophy
(27)Pump minimum recirculation
(28)Pump discharge line PZAHH & TZAHH set point
calculation
(29)Pump PSV/TSV/TRV sizing
(30)Pump casing vent & drain connections
(31)Cavitation / Back flow or Reverse flow
(32)Pump startup procedure based on impeller types
(33)Pump capacity & head control keeping fixed
impeller diameter
(34)Pump capacity & head control keeping speed
constant
(35)Pump capacity & head control using recirculation &
orifice
(36)Pump casing fluid temperature rise during
recirculation
 7|Page

(37)Pump capacity control using VFD or Gear Drive

(38)How to read pump vender curves (characteristic
curves)?
(39)How to generate pump performance curves using
vendor pump characteristic curves?
(40)Complete pump design example
(41)Pump series operation & H Vs Q curve generation
(42)Pump parallel operation & H Vs Q curve generation
(43)Pump affinity laws detailed explanation
(44)Useful Standard Data and Charts
8|Page

UNIT CONVERSION

FORCE:

F=ma=kg*m/sec2=1 kg*1 m/s2=1N

[Acceleration due to external force]

F=mg=1kg*9.8 m/s2=9.8 N

[Acceleration due to gravity force]

1 kgf=9.8 N

1 kgf means force applied by 1 kg mass on a surface

due to gravity effect.

1 dyne (Dyne) =1gm-cm/s2 [CGS Units]

1 N = 1 kg. M/s2

9.81 N =2.2 lb. = 1.0 kg

1 N = 105 Dyne

1 Lbf = 4.448 N

1 Ozf = 0.28 N
9|Page

MASS:

M=1 kg=1000gm=2.207 lb

1 pound (lb.) = 453 grams = 0.543 kg

1 Ounce, Avoirdupois = 28.34 grams =0.02834 kg

PRESSURE:

1 atm=1.01325 bar = 101.325 kPa =14.7 Psia

1 atm1 bar=10m of water column

1-inch mercury column = 3377 Pa = 3.377 kPa =

0.0337 bar

1-inch water column = 248.82 Pa = 0.2488 kPa =

0.002488 bar

1 atm=760 torr

1 Pa = 1 N/m2

1 bar = 105 Pa = 100 kPa =14.5 psi

10 | P a g e

1 psi = 6.895 kPa

1 kg/cm2 = 98.07 kPa = 0.9807 bar = 14.2 psi

1 Dyne/cm2 = 0.1 Pa = 10-4 kPa

Power:

1 Joules/sec=1 Watt

1 KW=1000 Watt=1000 J/s

1 HP=746 Watt

1 BTU=1055 Joules

1 KW=3412 BTU/m =1.341 HP

R=8.31447 J/k-mol = 8.31447*107ergs/k-mol

1 cal=4.186 J

1 joules=1N-m=1 kg-

1 erg=1 Dyne-cm=1*10-7J [CGS units]

11 | P a g e

TEMPERATURE:

°F=1.8 °C+32

°C=°k-273.15

°R=°F+459.69

K=°C+273.15

Viscosity (Dynamic) or absolute viscosity:

= Pa.s

1 Pa.s = 1 N.s / m

1 Pa.s = 10 Poise (P) = 1000 cP

1 Stokes = 10-4 m2/s

12 | P a g e

or

1 cSt=

VOLUME:

1 milliliter (ml) = 1 cm3

1 dm3 = 1 liter

1 gallon (US) = 3.785 liter (Petroleum)

1 gallon (UK) = 4.546 liter (Petroleum)

1 m3 = 219.969 gallon (UK liquid)

1 m3 = 264.172 gallon (US liquid)

1 Barrel = 42 gallon (US) = 159 liter

1 ft3=28.316 liter

1 m3=1000 liter

1 BPD (Barrel per Day) =160 liter/day (approx.)

13 | P a g e

1 BPD=

1 BPD=0.00666

1 gpm =3.785 liter/min

1 gpm=3.785*60=227.1 liter/hr

1 gpm=0.227

1 m3 = 1000 liter =35.31 ft3

1 ft3 = 28.32 liter

1 liter = 1000 ml = 1000 cc = 1000 cm3

Pressure (column):

1 inch of Hg= 0.0334 atm

1 inch of Hg=13.60 inch of water (H2O) column

1 inch of H2O=0.002458 atm

1 inch of H2O=0.0361 Psi

1 m of H2O=0.1 bar
14 | P a g e

Pound force:

It is defined as that a standard gravitational field

exerts a force of one pound on a mass of 16 ounces
(16*28 = 1 pound)

The standard acceleration of free fall in FPS unit is

1 pound force (1 lbf) =32.174 lb-ft/

Note:

The unit for work and mechanical energy in the FPS

system is the foot pound force (ft-lbf)

1 HP= (Horse Power) =550 ft-lbf/s

ENERGY:

1 N.m = 1.0 J

1 Watt = 3.413 BTU/hr.

1 BTU/hr. = 0.2931 Watt

1 hp = 745.71 Watt

1 BTU = 1055 J
15 | P a g e

1 Cal = 4.18 J

I Joule (J) = 107 ergs

1 KW-hr =3600 kJ

HEAT CAPACITY:

1 BTU/lbm.0F = 4188 J/kg.0C

1 Cal/g.oC= 4188 J/kg.oC

FLOWRATE:

1 gallon (US)/hr. = 3.78 liter/hr.

1 bbl. (US) / hr. = 159 liter/hr. = 42 gallon /hr. = 1

barrel/hr. = 0.0417 BPD (Barrel Per Day)

= 0.159 m3 /hr.

1 liter/s = 15.9 gpm (gallon per minutes)

1 BPD (Barrel Per Day) = 0.0066 m3/hr.

THERMAL EXPANSION:

Liner Expansion ΔL= α* L0 * ΔT

Area Expansion Delta (A) = γ* A0 * ΔT

Volume Expansion Delta (V) = β* V0 * ΔT

16 | P a g e

β=3*α

CONSTANTS:

Universal gas constant Ru = 8.314 kJ/kg.mol.K

Universal constant of gravitation G = 6.67 * 10 ^-11

Nm2 /kg2

Standard Gravitational acceleration g = 9.8 m/s2 = 9.8

N/kg = 32 ft. /s2
17 | P a g e

Pressure measurement:

If we apply force to the surface of a liquid by a piston

of cross-sectional area ‘A’ than applied pressure on
the liquid surface inside the cylinder is P=F/A
If F=10 Newton
& A=1 m2

Then

Basic unit of
18 | P a g e

Basic unit of

In FPS unit:

1m=3.28ft

Atmospheric pressure:
It’s a force exerted by the weight of the atmosphere
on a unit area.
19 | P a g e

1 atm=14.7Psia at sea level

1 atm=1.01325 bar
1 atm=101 KPa
1 bar=100 KPa
Pressure at height ‘h’ (P) = ρ g h
Where ρ=density of Air
g=9.8 m/sec2
20 | P a g e

h=700m

ρ ρ

Now

Therefore, pressure at height H=700 experience by

man or any other things.

=0.9185 bar
21 | P a g e

Absolute Pressure (bar/Psia):

Absolute pressure on anybody or place is the sum of
palm at sea level and the pressure exerted on
anybody or place.

In the diagram a man is standing is close chamber

and a pressure is exerted by pressure producing
machine (Air compressor) & you read pressure gauge
reading mounted on the closed chamber is 2 barg
(‘g’ is added to indicate “gauge”)
Then absolute pressure (bar) = P (Atm) + 2 barg
At sea level= 1.0132 bar + 2 barg
=3.0132 bar
But if we are not at sea level and our plant or
equipment is installed at such location, where height
(elevation) of location from the sea level is let say
700m then
22 | P a g e

Absolute pressure (bar) = P (Atm) +2 barg

= 0.9185+2 barg
= 2.9185 bar
An engineer should not make mistake for calculating
the absolute pressure at the different elevation from
mean sea level (MSL). Before calculating absolute
pressure, first calculate the atmospheric pressure at
the location where plant or equipment is installed,
based on the height from mean sea level.

Gauge pressure (barg/Psig):

It’s a pressure you read from pressure gauge
mounted on any types of equipment. Since, pressure
gauge is calibrated to set at zero reading with
reference to the atmosphere before installing on any
equipment or line.
23 | P a g e

Gauge pressure tells us the pressure of the fluid

inside the vessel/equipment/pipeline.
Psig=Psia-P (atm)
Vacuum:
It’s a pressure less than atmospheric pressure. If the
pressure gauge reading mounted any vessel/
pipeline or equipment is negative. Then its vacuum
full vacuum will be when pressure gauge reading will
be- 1.0 barg

Liquid specific gravity:

It’s a ratio of fluid density to density of water at
15.6°C

Sp.gr of water =1.0

Liquid specific gravity tells you, that any fluid (liquid)
is how many times heavier or lighter than water.
24 | P a g e

Gas specific gravity:

It’s a ratio of gas density to density of air at same
temperature & pressure.

Exp. Molecular weight of methane (CH4), MW=16

Gas specific gravity tells you that a gas is how many

times are heavier or lighter than Air.
In above example air is double heavier than methane
gas.
25 | P a g e

Pressure Head (m):

Or

Or

To know how much head, pressure, and power

required for the pump @ different specific gravity
fluid?
Liquid (1) Liquid (2) Liquid (3)
26 | P a g e

Let say we need to develop 10m head, then

For liquid (1)
Required pump discharge pressure

For liquid (2)

=2bar

For liquid (3)

This means that if the pumping fluid is heavier than

required discharge pressure developed by any
centrifugal pump increases. Consequently, power
consumption increases.
If the pump discharge pressure Pd=10 bar. Then head
developed by the pump for
27 | P a g e

Liquid (1)

Liquid (2)

Liquid (3)

For heavier liquid pump will develop less head with

constant power input & rpm of motor.

Pump Heads:
When the pump is not under running conditions,
then all the heads are called static heads.

Suction Static Head (HS)1:

Height in meter from the pump suction centerline to
the liquid level in the suction vessel.
28 | P a g e

Discharge Static Head (HS)2:

Height in meter from the pump suction centerline to
the liquid level in the discharge vessel.

Total static head (ΔHs):

It’s a difference between the discharge static head
and suction static head . This is
used to calculate the initial startup power required
to pump the fluid

Initial pump power requirement=

m= mass flow rate, kg/sec

= pump efficiency

When the pump starts running, then all head

becomes dynamics & called dynamic heads. Initially,
the power requirement is less, since there is less
flow rate, less friction loss in the suction & discharge
piping, less velocity head requirement in suction and
discharge piping. But, when the flow increased, then
the entire above variable mentioned increase, due to
which power requirement keep on increases. To find
the power requirement by the pump at particular
flow we need to read the power on the power curve
29 | P a g e

corresponding to pump resistance curve (system

resistance curve) and pump head vs. flow curve
intersection points.
30 | P a g e

LEGEND & ABBRIBIATIONS

 31 | P a g e

(1) Bernoulli’s Equation Application

First, we need to understand

What is Bernoulli equation?

And why we use it and what are its assumptions and

limitations.

It’s an Energy balance equation for incompressible

fluid flowing through pipe or closed channels.

Assumption:

1-Fluid behave ideally

2-Density of fluid is constant
3-Mass is constant
4-Volume is constant

Applications:

It’s used for calculating the pressure gain or loss and

kinetic energy gain or loss due to change in
elevations.

It’s also applicable to calculate the velocity head or

pressure head loss in piping and fittings.
32 | P a g e

We can use this equation to convert pressure head

into velocity head and vice a versa.

Limitations:

It’s applicable for incompressible fluids (liquids),

where density remains constant. It’s not applicable
to compressible fluids (gases or vapors).

Consider a section of pipe in the pump discharge

piping from point 1 to 2.
Energy balance for a section of pipe from (1) → (2)
Energy in = Energy out
E1 = E2
E1 E2 constant
E1 E2 constant
E1 Pressure energy at point (1) + K.E at point (1)
+P.E at point (1)
33 | P a g e

E2 Pressure energy at point (2) + K.E at point (2)

+P.E at point (2)
If the pump discharge pressure “P”
Then pressure energy input by pump in the fluid
streams
For pursing liquid volume “V” is =PV
We know work done=P.ΔV
1
Therefore E1 P1 V 2
m V1 2 mg 1

1
E2 P2 V 2
m V2 2 mg 2

E1 E2
1
P1 P2 V 2
m V1 2 V2 2 mg

Dividing by “m” on both side

V 1
P1 P2 V1 2 V2 2 g 1 2
m 2

Bernoulli’s Equation
If the pipe is on horizontal plane & 1 2

Then equation ρ

ρ
P 1
ρ 2
V2

P V2
ρ
=pressure head & 2
=velocity head

For ideally liquid using this equation, we can convert

pressure head into velocity head & vice a versa.
 34 | P a g e

But for real liquid & real process equation becomes

P 1
ρ 2
V2

K=energy loss constant or factor of loss for

conversion of energy in pipes & fittings

Continuity equation:
It a mass balance equation for flowing
incompressible fluids in the pipe section from 1 to 2.
Mass Balance
Mass in at point (1) =mass out at point (2)
m1 m2
ρV1 A1 V2 A2
This is a Continuity Equation.

(2) Centrifugal pump suction & Discharge piping

size calculations
Normal pump suction piping recommended
velocity is =1.0m/sec & discharge piping velocity
is =2.5m/sec
First of all, we need to calculate the Reynolds
number for suction & Discharge piping for given
flow rate & assumed pipe size for initial
calculation.
35 | P a g e

Assumptions:
1- Suction piping equivalent length is 10 meter
2- Discharge piping equivalent length is 100 meter
3- Required pump flow rate 4 m3/hr
Let first calculate the initial suction and discharge
pipe size requires 4 m3/hr flow rate using a simple
formula:
m3 1m
VA m sec
D2

3
m3 sec 1m sec D2

1
D 3

1 1 1 1
D
2 31 12 31

1
D 12 1
3m

D 3 mm 2 inch
36 | P a g e

We can calculate the pump discharge piping size by

using the above method or we can use engineering
design thumb rule discharge for calculating pump
discharge pipe size, which is half of the suction pipe
as per the thumb rule.

Therefore discharge pipe size= 1inch

For Suction piping

ρVD 1 1
e 1
Turbulent

flow

Pressure drop will be calculated using Darcy

ρfLv2
Equation ΔP 2D

Here f=moody friction factor for turbulent flow when

For laminar flow f= when e

e

For calculating friction factor “f” for turbulent flow,

either use moody chart which is e Vs D

Where

D is ID of pipe & ε is pipe material roughness factor

Or use imperial equation.

37 | P a g e

In the imperial equation, you have to use heat & trial

method for different value of ‘f’ so that equation

LHS (Left Hand Side) =RHS (Right Hand Side)

Once you know the friction factor ‘f’ you can use
Darcy equation to calculate the friction pressure
drop in suction & discharge piping for given flow rate
& the pipe sizes.

ρfLV2
Darcy equation is ΔP 2D

Where L=equivalent length of piping

D=ID of piping

V=fluid velocity in piping

Ρ= density of fluid

f= friction factor

If all units of variable in this equation are MKS units

then calculated value of ΔP (Pressure drop) would be
in Pascal.

1 bar=100 KPa

1 bar= 100,000 Pa
38 | P a g e

Note:
Dynamic or Absolute Viscosity =1 CP

We know by Newton’s Law of Viscosity

Inserting MKS units

(MKS unit)
1Pa.sec=1000cP
1cP= Pa.sec

If the frictional pressure drop calculated value in

suction and discharge piping is more than the
allowable value of pressure drop as per the system
design and NPSHA calculation, then we can increase
the piping sizes. But suction fluid velocity should
not fall below 0.8 m/s.
 39 | P a g e

(3) What is pump?

In simplest language pump is a pressure producing
machine. It takes suction fluid at low pressure &
delivers at the higher pressure from discharge side
by using any of the mechanical power supplying
devices such as an electrical motor, gas engine and
turbine. Electric Motor, gas engine or turbine
connected with the pump by shaft coupling as shown
in the figure. Power is supplied to the pump in the
form of BHP [Break Horse Power] and pump utilizes
it in the form of WHP [Water Horse Power].

Electrical Power Supply to Motor in – KW [Kilo Watt]

Electrical Motor Rated in- Hp [Horse Power]
Electrical Motor Supply Power to Pump in – BHp
[Break Horse Power]
Pump Produce- WHP [Water Horse Power]
WHP- It’s a useful work done by pump to produce
pressure.
 40 | P a g e

Pump Efficiency: Ratio of WHP to BHP

(4) Pump parts:

1- Impeller vanes
2- Impeller eye
3- Pump casing
4- Diffuser section
5- Impeller
(5) How Pump Produce Pressure?
Pump impeller rotates; pump suck liquid in the
suction, liquid enters into the pump through the
impeller eye & rotates on the impeller surface.
Impeller increases the fluid momentum & kinetic
energy by centrifugal action while rotating with
 41 | P a g e

angular velocity. Impeller vanes guide the fluid

toward the periphery of the impeller. High kinetic
energy fluid leaves the impeller surface & enters into
the low cross-sectional area in the pump casing &
moves towards the diffuser section of the larger area
where the fluid velocity (kinetic energy) reduces &
get converted into the pressure energy (pressure
head). Conversion of kinetic energy to pressure
energy is as per energy conservation law. In this way,
pump produces pressure using the mechanical
power supplied by Electric Motor or any other
devices.
(6) How to design Pump? What are the design
parameters we need to calculate?
Initially, we know that how much head [in meter] we
have to develop and flow rate [in m3/hr or liter/hr] is
required to transfer liquid. Here head means the
vertical height from the base of the pump to the
vessel and tank liquid level, where we have to
transfer liquid from the suction vessel.
The required flow rate is calculated on the basis of
liquid volume [in m3 or liter] required to transfer per
hour.
For required flow rate & head (discharge pressure)
to design/sizing a centrifugal pump
 42 | P a g e

We need to calculate following parameters:

1-NPSHA[Net Positive Suction Head Available]
2-Differential Head/ Discharge Pressure
3-Required Power Consumption
4-Impeller Diameter
5-Design flow rate/ Shut off Head
6-Design pressure/Design Temperature

(7) What is NPSHA:

NPSHA= Net Positive Suction Head Available.

Simply, it’s a pressure gauge reading at the suction
of the pump. More precisely it’s a pressure head
(suction pressure) in meter available at the suction
of the pump when the pump not running. When the
pump starts & run at certain speed NPSHA will
reduce by the pressure drop in the suction piping
due to friction and required velocity head for fluid
movement in the suction piping and reach to the
suction of the pump.

It is calculated by Process Design Engineer using

engineering tools & calculations.
 43 | P a g e

(8) What is NPSHR?

NPSHR= Net Positive Suction Head Required Simply,
It’s a pressure head (suction pressure) in meter
required to run the pump without cavitation &
delivering required flow rate and producing required
discharge pressure. NPSHR provides by vender based
on the pump test run performed in the vendor
laboratory for testing equipment based on water as
the fluid.

(9) How to calculate pump Impeller diameter?

Suppose we want to through a cricket ball up a
certain vertical height, for that we need to through a
ball with some initial velocity so that our balls reach
up to the required vertical height. To calculate the
initial velocity, we can use the “equations of
motion”.
Pump impeller diameter is calculated based on the
concept of required initial discharge velocity to
achieve the height equivalent to required discharge
head. Recall the equation of motion”
” using this equation we can calculate the
required initial velocity “u”
Final velocity “V” will be zero at height “h”
 44 | P a g e

Therefore initial velocity will be m/sec if

Height[h] in meter and g is 10 m/sec2.
Use this velocity in meter,

where r= Impeller radius in meter

u= peripheral velocity of impeller m/sec calculated

by
= angular velocity of impeller
n= revolution per minutes [rpm].
Therefore, Impeller Diameter = 2* Impeller radius

(10) How to select pump impeller type?

Impeller type is selected based on the flow & head
requirement.
There are three basic types of impellers:

1-Radial: It is selected for high head and low flow

requirement
2-Axial: It is selected for low head & higher flow
requirement
3-Mixed: It is selected for medium head & medium
flow requirement.

Impellers could be open, closed, semi open

impeller.
 45 | P a g e

(11) Pump impeller geometry:

Pump impeller geometry includes impeller diameter
and impeller vanes types, forward lean, backward
lean or straight.
Axial impeller & vanes are like table fan.

(12) Pump affinity laws:

Pump affinity laws define the relationship between
the pump diameters, pump speed, and pump flow
rate, developed discharge head, power consumption
& NPHR.
If we know the pump flow rate, head, power
consumption & NPSHR at some speed with a fixed
diameter, then using pump affinity laws, we can
calculate the pump flow rate, head, power
consumption, NPSHR at different speeds.
 46 | P a g e

Similarly, for fixed speed pump, if we know the

pump flow, head, power consumption, NPSHR and
impeller diameter. Then, using pump affinity laws we
can calculate the pump flow rate, head, power
consumption, NPSHR at different impeller diameters.

(13) Pump Specific Speed:

Pump specific speed does not pump speed it’s a
dimensionless number related to pump impeller
geometry & types.

Where,

Ns= Pump Specific Speed

n= Pump rotational speed, rpm

Q=GPM

H=head in feet

We can use this equation to determine which

impeller design can best match the requirements of
a particular application.
47 | P a g e

Example: If we need an impeller that will produce

1000 GPM at 200 feet of head.

If we enter Q&H values in above equation & motor

speed 3600 rpm (based on 50 Hz frequency AC
power supply) we obtain a specific speed of 2140.
Based on this specific speed we can select the
geometry & type of the impeller.

(1500-3000)- Francis Impeller

(4000-8000)-Mixed Impeller

(9000-15000)-Axial Impeller
 48 | P a g e

(14) Pump Suction & Discharge Piping or Pump

Loop Schematic & PID
49 | P a g e

Pump Suction Side

1- Suction piping
2- Filter strainer in suction piping
3- Pressure and Temperature gauge in suction
4- Expander in suction
5- Pressure Differential Transmitter

Pump Discharge Side

1-Discharge piping
2-Reducer
3-Pressure and Temperature gauge
4-Pressure Safety Valve[PSV/PRV/TSV]
5-Isolation valve
6-Recirculation line connection
7-FCV[Flow Control Valve]
8-NRV[Non Return Valve/Check Valve]
9-PDT[Pressure Differential Transmitter]

Pump

1-Pump Casing
2-Vent connection on pump casing
 50 | P a g e

3-Drain connection at the side bottom of pump

casing
4-Priming connection on Pump casing, if the pump is
not self priming

(15) Pump suction & discharge piping hydraulic

calculation
The hydraulic calculation mean head loss (pressure)
and frictional pressure drop calculation in suction as
well as discharge piping of pump loop.

If the suction equivalent length of the piping is=

& discharge equivalent length of the piping is =

 Then frictional pressure drop in the suction piping

ρ
is

&
 Frictional pressure drop in the discharge piping is

Static head gain or loss can be calculated as:

 Head Gain =Liquid moving from a higher elevation
to lower elevation with reference to the pump
centerline
 51 | P a g e

 Head Loss= Liquid moving from lower elevation to

higher elevation with reference to the pump
centerline

Pressure drop across control valve can be calculated

as:
[Use FPS units]

(16) Pump control valve pressure drop calculation:

The pressure drop across the flow control valve in
the pump discharge line could be calculated using

control valve equation

The pressure drop across control valve varies with

the square of flow rate. It means, if the pump flow
rate is increased to double then pressure drop across
control valve will increase, approximately & four
times.
It can be calculated using the relationship
 52 | P a g e

Where
ΔP is in Psi; Cv = control valve flow coefficient;
Q=flow in gpm; sp.gr= fluid specific gravity

(17) Pump NPSHA calculation:

Pump NPSHA is calculated as:

If the suction tank is open to Atmosphere

1- NPSHA= [Atm. Pressure (m)]+ [Suction static
head ( ) in meter] – [Suction piping frictional
loss (m)]-[ Fluid vapor pressure at maximum
operating temperature] – [Piping Entry loss]-
[Piping Exit loss]

If the suction tank (vessel) is closed

2- NPSHA= [Suction pressure at minimum operating
pressure]+ [Suction static head at minimum
operating liquid level in suction vessel]- [suction
piping frictional losses]- [fluid vapor pressure at
maximum operating temperature]

If the suction vessel is open to atmosphere and

below the pump suction eye level (Negative Suction
lift)
 53 | P a g e

3- NPSHA=[Atmospheric pressure (m)]- [suction lift

(pump suction eye to liquid level height)]-
[Suction piping frictional losses]- [Fluid Vapor
pressure@ maximum operating pressure]-
[Piping Entry Loss]-[Piping Exit Loss]

(18) Pump discharge head calculation:

In this case reverse hydraulic calculation is
performed, i.e. form delivery point (A) to pump
discharge nozzle (B)

Pump required static discharge head= required

delivery pressure ‘P0’ + frictional pressure drop in
piping from (A) to (B) Design flow rate + discharge
static head
This is the pressure, which pump has to develop to
perform its duty.
 54 | P a g e

(19) Pump differential head calculation:

It’s a pressure difference across the pump suction
nozzle & discharge nozzle while pump is running.

Pump differential head=ΔH= [Discharge pressure

in (m)] - [Suction pressure in (m)]
This differential head is used to calculate the pump
power requirement.

(20) Pump shut off pressure calculation:

It is the maximum pressure developed by the pump,
if the pump is running & pump discharge valve is
closed.
Pump shut off pressure= [Maximum suction

pressure] + 1.20*[Pump differential head]

(21) Pump characteristic curves:

Pump curve provided by the vendor which includes
the head (based on impeller diameter) Vs flow,
 55 | P a g e

pump power, pump efficiency, NPSHR, curves are

called pump characteristic curves.
These curves provide the basic information of the
pump behavior. How pump discharge pressure,
power, efficiency, NPSHR will vary with change of
pump flow rate, impeller diameter.

(22) Pump performance curve:

These curves are produced, when the pump is
running at varying rpm, flow, suction pressure,
discharge line control valve percentage opening for
fixed suction & discharge piping size of the pump.
System resistance curve is plotted with vendor pump
characteristic curves for a fixed impeller diameter.
When system resistance is included in characteristic
curves then combined curved are called pump
56 | P a g e

performance curve. Now performance is obtained

corresponding to system resistance and H-Q curve
intersection point.

Pump system resistance curve:

System resistance curve is produced when the pump
is running i.e. pump is in Dynamic mode. It tells us
the total resistance in pump suction & discharge
piping system i.e. Frictional pressure drop &
required velocity head in the pump suction &
discharge piping. System resistance is plotted on the
same H-Q characteristic curves of the pump. It will
be system resistance Vs flow rate curve.

System resistance= [Frictional Pressure (Pf1) drop in

suction] + Piping system [Velocity head (Hv1) req. in
suction piping to achieve mini suction fluid velocity]
 57 | P a g e

+ [Frictional pressure drop (Pf2) in discharge piping

system] + [Velocity head (V2) req. in discharge piping
to provide minimum fluid velocity] + Pressure drop
across control valve

(23) Pump operating points:

When the pump is running at some rpm with fixed
impeller diameter then developed system resistance
curve will intersect flow Vs head curve at some
point. This point is called pump operating point.
Corresponding to this point we can read all the
performance variables of the pump. For the fixed
size of suction & discharge piping pump operating
point on H-Q curve will vary left or right by changing
pump speed (rpm), suction pressure, control valve
opening, flow rate and arrangement of suction and
discharge piping.

(24) Pump power consumption calculation:

Pump power consumption is calculated based on the
pump discharge flow rate, pump efficiency, density,
viscosity (dynamic) and differential head of the
pump.
 58 | P a g e

(25) Pump operating & control philosophy

It includes pump startup, shutdown & operating
parameter control system. Operating & control
philosophy of the pump explain how the pump is
started and stopped normally and during emergency
shutdown or operation emergency.
It also explains the various alarm & trip system,
primary & secondary safeguarding instrument &
mechanical items, their tag number, set points &
sequence of opening & closing of valves. Attachment
with this report should include (1) P&ID, (2) PFD (3)
PSFD (4) CEM (5) Vendor Curves (6) Pump Datasheet
(Process & Mechanical).
 59 | P a g e

(26) Pump minimum recirculation:

Recirculation means diverting flow back to pump
suction vessel from pump discharge. Recirculation is
required for startup & turn down operations.
Minimum recirculation is the minimum amount or
percentage of pump discharge flow diverted back to
pump suction vessel or suction line; which is the
minimum requirement to keep pump running
operation stable with minimum and within the
limitation of temperature rise in the pump casing or
recirculation loop. Minimum recirculation flow is 20-
35% of pump discharge flow for stable operation &
to avoid cavitation in the pump casing. Based on the
pump efficiency, power loss by the pump is
converted into heat for the conservative case.
 60 | P a g e

(27) Pump discharge line PZAHH & TZAHH set

point calculations:
Based on the pump shutoff pressure PZAHH
(Pressure Trip Alarm High High) is set at 90% of
pump shutoff pressure, whereas PAH (Pressure
Alarm High) is set at 80% of pump shut off pressure.
If the pump shutoff pressure is 100 bar, then PZAHH
set point will be 90 bar & PAH set point would be 80
bar.

[Pump Discharge Piping PZAHH, TZAHH, PAH and TAH Schematic

Drawing]

Pump discharge piping design pressure, class &

pressure rating at maximum operating pressure will
be based on the pump shutoff pressure. TZAHH
(Temperature Trip Alarm High High) will be set at the
temperature at 90% of the temperature at which the
 61 | P a g e

pressure rating of the discharge piping class will be

de-rated to the pump shut off pressure whereas TAH
(Temperature Alarm High) set point will be 10%
lower than the TZAHH set point.
Let say pump discharge piping is 150# & Pump shut
off pressure is 15 bar & maximum operating
pressure of the pump is 35° C.
At 0°C 150# piping rating as per API 526 & ASME
B16.5 pressure rating is 19 bar.
At 50° C, it is de-rated to 17 bar. If the temperature
rises further at 80°C or above 150# pressure rating
may de-rate below 15 bar. This means around 70-
75°C is limit. Therefore we can keep TZAHH set point
at 70°C & TAH at 65 or TAH set at 10% below TZAHH
set point.

(28) Pump PSV/TSV/TRV Sizing:

PSV/TSV is mounted either on the pump casing or on
the pump discharge line before flow control valve,
isolation valve and check valve to avoid catastrophic
failure of pump casing & discharge piping. PSV
(Pressure Safety Valve) is a mechanical item used as
ultimate equipment safeguarding item during an
emergency, fire case. TSV/TRV (Thermal Safety or
Relief Valve) is installed on the pump casing or
 62 | P a g e

discharge or suction piping to safeguard against

failure due to liquid thermal expansion in piping. The
size of T V is normally fixed and taken as ¾”. As per
design engineering practice, ¾ inch TRV size is found
suitable for wide range of process fluid in piping.

(29) Pump casing vent & drain connections:

Vent & drain point is provided on the pump casing
top & button (side button). A vent is used to remove
the vapor generated or air pockets. Drain connection
is used to drain the casing for taking pump into
maintenance.

(30) Cavitation/ Back flow or Reverse flow:

Cavitation is a phenomenon of vapor formation, air
ingress or bubble formation and bursting on the
63 | P a g e

impeller surface or inside the pump casing or at the

pump suction line.
Cavitation causes damage to pump impeller surface,
head loss, flow loss & pump casing heating.
Cavitation occurs majority in the liquid pump when
the NPSHA at the pump suction is negative.
NPSHA= [Suction pressure head -friction loss-Vapor
pressure of liquid].

Refer to the following plot. If the available suction

pressure at the pump suction is below the vapor
pressure of pumping fluid. In such case, liquid start
boiling, flashing, and forming bubble & cause
cavitation. To avoid these problems, we should keep
the suction pressure at the inlet of the pump above
the vapor pressure of the liquid at maximum
operating temperature for more conservative design
calculation.
 64 | P a g e

(31) Pump startup procedure based on impeller

types:
There are three basic types of impeller (1) Radial (2)
axial (3) mixed
1-If the impeller is Axial, then pump could be started
by keeping the discharge valve full open.

2-If the impeller is Radial, then one should start

pump keeping discharge valve full close to let it
develop discharge pressure and flow. Once the
discharge pressure is fully developed, discharge
valve could be open slowly to its fully open
position.
3-If the impeller is a Mixed type, then one should
start the pump keeping discharge valve partially/
cracked open. The moment flow is fully developed;
 65 | P a g e

discharge valve could be open slowly to its fully

open position.
(32) Pump capacity & head control keeping fixed
impeller diameter:

When the pump impeller diameter is fixed, pump

capacity & head could be controlled by varying the
motor rpm using VFD (variable frequency drive) or
varying the resistance in the discharge line as
represented in the following diagram. The resistance
in the discharge piping could be varied by changing
the percentage opening of the control valve. As
shown in the following diagram, if the speed
increases pump discharge pressure increases, flow
also increases to some extent but not too large.

Pump discharge pressure could be changed by

increasing/decreasing the resistance in the discharge
piping either by throttling the flow control FCV) in
the pump discharge piping or changing the discharge
piping size. By reducing the piping size,
resistance/pressure drop in the piping increases.
66 | P a g e

1-When the rpm of motor increased or decreased

then operating point either shift vertically upward
on the higher rpm pump curve or straight vertically
downwards on the lower rpm curve.
67 | P a g e

P= Initial operating point

Pi=operating point on variation of percentage
opening or rpm
 68 | P a g e

2-When the control valve percentage opening is

increased, by keeping the fixed rpm, then
operating point (P) shift right along the H-Q curve.
On the other hand, if the percentage opening of
control valve decreased, then operating point (P)
shift to the left along the H-Q curve.
3-If both rpm (motor) and control valve percentage
opening is increased then the operating point (P)
will move right side between the horizontal &
vertical direction as shown in the diagram.

(33) Pump capacity & head control keeping speed

constant:
When the pump drive motor speed is kept constant,
then pump capacity & head could be controlled by
 69 | P a g e

changing the control valve percentage opening and

changing the impeller diameter. Changing impeller
diameter is a one-time capital investment, whereas
throttling down (reducing percentage opening) the
control valve is continuous power loss due to the
pressure drop across control valve.
Initially, we try to accommodate the required pump
flow and head for the installed impeller diameter by
changing the pump motor rpm and control valve
percentage opening. If, it is not possible by changing
rpm of the pump motor and percentage opening of
the control valve. Then only last option we will use to
change the impeller with the different diameter.
(34) Pump capacity & head control using
recirculation & orifice:
 70 | P a g e

When pump driver motor rpm is fixed and impeller

diameter is also fixed, only option to control the
pump capacity and pump discharge head is either
recirculation or installation of RO (restriction orifice)
plate in the pump discharge line. But capacity and
head control will be on the cost of power loss.
Because in recirculation and restriction orifice
pressure drop, there will be continuous power loss.
This method should be used as last option for
capacity and head control.

(35) Pump casing fluid temperature rise during

recirculation:
During recirculation of flow, the pump is still running
at same rpm but the pump is wasting energy in flow
recirculation and pressure drop across flow control
valve since flow control valve percentage opening is
adjusted for flow recirculation.
Therefore if the pump efficiency at the operating
point during recirculation is 60% then remaining 40%
energy will be wasted in terms of pressure drop
across flow control valve and doing work for
recirculation flow and mechanical losses inside the
pump casing which get converted into heat &
increase the temperature of fluid in the pump casing
71 | P a g e

or in recalculating loop. The flow recirculation

percentage should be kept in such a way that
temperature rise of the fluid (when the pump
started with recirculation) should not rise beyond
the TZAHH installed on the pump discharge piping. If
the temperature rises very soon above TZAHH set
point after starting the pump, then before fully
opening the flow control valve in the pump discharge
line, the pump will trip (stop) due to TZAHH action.
In such case, the operator will not be able to start
the pump and run it continuously. When such type
of case happens then what to do

In such case either we need to increase the TZAHH

set point or increase the percentage of recirculation
flow or increase the fluid volume in the complete
recirculation loop (by changing the location of
recirculation line connection in pump suction piping
or vessel) to avoid the high temperature rise in the
 72 | P a g e

pump casing/ discharge time/ recirculation loop and

temperature trip (TZAHH) which shut down cause to
stop the pump. Since TZAHH is routed by hard wire
to PLC system which cannot be overridden during
pump startup unlike DCS control system.

(36) Pump capacity control using VFD or Gear

Drive:
 73 | P a g e

Pump rpm could be changed by using gear system or

installing VFD (Variable Frequency Drive) for
controlling or changing the main electrical power
frequency. VFD is similar to the smooth rotating
knob of ceiling fan regulator, which is used to change
the rpm of the fan. VFD could be used to fine-tune
the required pump rpm; whereas gear drive could
change the rpm of the pump only in certain fixed
ratio. This is the reason VFD is more energy efficient
than Gear Drive. But initial capital investment for
VFD is higher than the Gear Drive (Mechanical). But
in long run VFD saved a lot of power & could be used
to fix rpm at absolute desired or required rpm.
(37) How to read pump vender curves
(characteristic curves)?
To understand & read pump curve, first of all, we
should have a general idea of shapes of pump curves
like H Vs Q, efficiency, NPSHR, power, resistance.
As per affinity laws at a constant speed (m) & at
constant impeller diameter (D)

(linear curve)
(square curve)
(cubic curve)
74 | P a g e

H or ΔP or
Therefore H Q
[Head] [Flow] curve will be reverse square curve
shape slop of the H Q curve depends on the
impeller type and geometry.
 75 | P a g e

1- Radial impeller[ H Q] curve is quick falling curve

(High Head low flow range)
2- Axial impeller [H Q] curve is slow falling curve.
(medium head & higher flow range)
3- Mixed impeller [H Q] curve slop is between
Radial & Axial (medium Head & Medium flow range)
 System resistance Flow (Q) curve is square or
parabolic shape
Starting point (P) of system curve depends on the
suction static head available at the inlet of the pump
suction. If suction pressure is zero than system curve
will start from the origin (0, 0) like curve (B).
If suction pressure is “P” then system curve will start
at point P in diagram curve (A). System curve tells
 76 | P a g e

you the pressure drop (resistance) variation in the

suction & discharge piping loop (including pump
casing) when the pump is running (pump is in
dynamic mode).

Since system curve is produced only when the pump

is running, without resistance in the discharge piping
pump will not develop any head (discharge pressure)

 NPSHR flow[Q] curve

Curve tells us that initial NPSHR is higher when the
flow increases towards the BEP then NPSHR
decrease. NPSHR is minimum at BEP (best efficiency
point) as shown point (P) on NPSHR curve.
 77 | P a g e

As the flow increase & pump operating (intersection

point of system curve & H-Q curve) point moves
right to the BEP, then NPSHR starts increasing. Once,
flow increase beyond the sweet zone range (which
20-30% left of BEP & 10-15% right of BEP on the
pump H Q curve) NPSHR increase rapidly.

 Power Flow curve

The power curve is cubic shape continuously rising
curve almost similar to the NPSHR curve. By
increasing flow rate, power consumption
increases.
 78 | P a g e

When flow increases further beyond the” sweet

operating zone”, power requirement or consumption
increased to a large extent. This is called “pump run
out condition” operation of the pump at run out
condition is avoided due to excessive power
consumption, low efficiency, high vibration & more
powerless.

 Efficiency flow curve

Efficiency curve is either parabolic shape or half
circle shape as shown in two diagrams. In vender
provided pump characteristics curve either of these
two types of efficiency curve is shown in combined
pump characteristics diagrams.
79 | P a g e

Efficiency is maximum at the BEP & average high

when the pump operating point is in sweet operating
zone. Sweet operating zone means; where the pump
operation is stable and efficiency is high.
 80 | P a g e

(38) How to generate pump performance curves

using vendor pump characteristic curves?
The vendor gives us the pump characteristic curves
as shown in diagram (A). The vendor gives H-Q curve
for different impeller diameters. One curve at rated
or selected impeller diameter, the second curve at
higher diameter & third curve at lower diameter
then selected impeller diameter keeping pump
speed constant (Design Speed).
Other characteristic curves of the pump like power,
efficiency, NPSHR are fixed shape curve for the
particular selected geometry of the impeller. Only H-
Q curve shifted up & down on Y-axis (pump head)
axis by changing the impeller diameter and pump
rpm.
Vendor selected pump impeller diameter such that
our required design flow rate & pump discharge
head falls on BEP (Best efficiency point) on the pump
H-Q curve. The cut point shown on the H-Q curve for
the selected impeller diameter tells us the BEP point
for our design flow rate and discharge pressure
required for the process. As other pump
81 | P a g e

characteristic curves shapes are fixed for specific

impeller geometry i.e. radial, mixed, axial etc.
Therefore, corresponding to BEP point marked on
the H-Q axis curve as explained above the power
requirement, efficiency, rpm and NPSHR could be
read from the vendor pump characteristic curves.
The length of the sweet zone (“_____”) marked on
the selected impeller dia. H-Q curve on both side of
the BEP point depends on the types of selected
impeller geometry.

For radial types of impeller sweet zone length is

small as compared to mixed & axial types of the
82 | P a g e

impeller. For the axial type of impeller, the length of

the sweet zone is maximum among all other types of
impeller geometry.
Length of sweet zone tells us the stable operating
range of pump with average higher pump efficiency.
Now where will be the operating point on H-Q curves
when pump run; depends on the resistance
(pressure drop) in the suction & discharge piping.
Therefore, for new pump installation suctions &
discharge piping size should be selected in such a
way that system resistance curve intersects the
pump H-Q curve preferred in BEP point or left of BEP
point on H-Q curve sweet operating zone.
83 | P a g e

For the entire range of pump operation system

resistance curve preferably intersect H-Q curve
within the sweet zone (A---B) as shown in the
diagram. Pump system resistance curve developed
when the pump is in running condition; since
pressure drop (resistance) develops in the suction &
discharge piping due to friction, fitting loss, velocity
head required. If the pump is not running then there
is no friction (which occurs due to fluid flow) and no
velocity head required.
When the pump is not running the pump curve will
be like shown in figure (2)
 84 | P a g e

(39) Complete pump design example:

ρ
Piping

Fitting

Total suction piping & fitting+ discharge

piping & fitting
Total suction +
85 | P a g e
86 | P a g e

= It represents the energy consumed or lost due

to the velocity of the fluid moving through the
system.
are linked & connected because is used
to calculate .

Pump is parallel:
87 | P a g e
88 | P a g e

Pump is series:
89 | P a g e
 90 | P a g e

(40) Pump series operation & H Vs Q curve

generation:
Pumps are connected in series to obtain higher
discharge pressure with same flow rate as delivered
by one pump.
It means it required pump discharge head is
increased for the same flow rate, and then we need
to install another pump in series with the first pump
of same flow rate.
The series arrangement means the discharge of (1)
pump is suction for a second (2) pumps.
 91 | P a g e

To draw series operation curve (B)

flow Pump Pump (1)&(2) in series

(Q) (1) (2) this head
head head

Note down the at least (5) different flow rates and

corresponding head from H-Q curves of both
individual pumps. Then draw both pumps is series
curve by keeping the same flow rates points and
head by adding the head of both the pumps at
corresponding flow rates as shown in the table. Take
flow at x-axis and combined head at Y-axis.

(41) Pump parallel operation & H Vs Q curve

generation:
Pumps are connected in parallel to obtain higher
flow rate with same discharge head. It means if the
required pump discharge flow rate is increased for
92 | P a g e

the same discharge head. Then we need to install

another pump in parallel with the first pump of the
same head.
The parallel arrangement means suction of both the
pumps are individual separate but both pump
discharge piping is connected to one discharge line
using T- connection as shown in the diagram.
It is mandatory to have same discharge head
according to flow rate or same H-Q curve to connect
them in parallel. If different than we need to install
an orifice plate in the discharge line of the higher
head pump to drop the pressure so that both pump
discharge line pressure is same before mixing or
connected to single discharge piping/ pipeline. If the
pressure is not equal than higher discharge pressure
pump will create back pressure or resistance for the
lower discharge pressure pump flow to enter into
mixture or single final piping
 93 | P a g e

To draw parallel operation pump (B)

Head Pump Pump (2) (1)&(2) parallel
(H) (1) flow flow q combine flow
Q

Take (Q+q) on x-axis & head on Y-axis and draw the

curve of combined parallel operation curve.

(42) Pump Affinity Laws Detailed Explanation:

Pump affinity laws explain the relationship between
flow, head, rpm power, pump impeller diameter and
NPSHR when the pump is under running condition.
By using the affinity law relationship you can predict
the flow, head, NPSHR, power requirement of pumps
by varying the pump impeller diameter and pump
driver motor rpm.
94 | P a g e

As per affinity laws

For two different running conditions

Similarly

For two different running conditions

If changes are made to both Impeller diameter and

pump speed (rpm) the equations can be combined
to:
95 | P a g e

Note:
The affinity laws are valid only under conditions of
constant efficiency.
Head losses in suction and discharge pipes
respectively
Static pressure measured at suction and
discharge branch respectively.
Static pressure above suction & discharge
liquid level, respectively.
Vapor pressure of pumping fluid.

ρ
(Bernoulli’s Equation)
96 | P a g e

1-To get the head of inlet equation shown in above

table, apply Bernoulli equation at two points (1) &
(2) shown in the diagram above.
Pe Ve 2 PS VS 2
e S HVS
ρg 2g ρg 2g

To get the heat at the outlet, apply Bernoulli

equation between point (3) & (4) shown in above
diagram
Pa Va 2 Pd Vd 2
Hd ρg a 2g ρg d 2g

Bernoulli’s equation for pump suction & discharge

two points
Pd PS Vd 2 VS 2
H ρg d s 2g

Vd VS Fluid velocity in discharge & suction piping

NPSHA Total dynamic head Head at outlet
97 | P a g e

ρ
ρ
98 | P a g e

or the liquid level e, which is necessary for

the plant to operate properly must be calculated
from the condition PSHA
 Equivalent length of straight pipe for valves and fittings (m)

4 4.0 1.4 1.7 5.2 6.4 4.0 33.6 0.8 5.5 11.6 12.8
3 3.4 1.2 1.2 3.7 5.2 3.4 24.1 0.6 5.5 8.2 10.4
2½ 2.8 1.1 1.0 2.8 4.0 2.8 18.9 0.5 5.5 6.7 8.8
2 2.6 1.1 0.8 2.3 3.7 2.6 16.5 0.5 5.5 5.8 8.2
1 1/2 2.3 1.0 0.6 1.7 3.0 2.3 12.8 0.4 5.5 4.6 6.1
1 1/4 2.0 1.0 0.5 1.4 2.7 2.0 11.3 0.3 5.5 4.0 5.5
1 1.6 0.8 0.4 1.0 2.0 1.6 8.8 0.3 5.2 3.4 2.3
¾ 1.3 0.7 0.3 0.7 1.6 1.3 7.3 0.2 4.6 2.7 2.0
(43) Roughness factor:

1/2 1.1 0.7 0.2 0.5 1.3 1.1 6.7 0.2 4.6 2.4 1.5
3/8 0.9 0.6 0.2 0.4 1.1 0.9 6.7 0.1 4.6 2.2 1.4
Pipe size
99 | P a g e

1/4 0.7 0.5 0.1 0.2 0.7 0.7 6.4 0.1 3.9 2.2
Regular Long Regular Line Branch Regular Globe Gate Angle Swing

Screwed
fitting
90° radius 45° flow flow 180° check
Elbows 90° Tees Return Valves Straine
bends r
 10 4.3 2.4 2.7 1.6 9.2 4.3 2.4 94.6 1.0 36.6
Equivalent length of straight pipe for valves and fittings (meter)

8 3.7 2.1 2.3 1.4 7.3 3.7 2.1

79.3 1.0 27.5
6 2.7 1.7 1.7 1.2 5.5 2.7 1.7
58.0 1.0 19.2
5 2.2 1.5 1.4 1.0 4.6 2.2 1.5 45.8 0.9 15.3
4 1.8 1.3 1.1 0.9 3.7 1.8 1.3 36.6 0.9 11.6
3 1.3 1.0 0.8 0.7 2.9 1.3 1.0
28.7 0.9 8.5
2 1/2 1.1 0.9 0.6 0.6 2.3 1.1 0.9 23.5 0.8 6.7
2 0.8 0.5 0.5 2.0 0.9 0.8
0.9 21.4 0.8 6.4
1½ 0.7 0.7 0.4 0.5 1.6 0.7 0.7 18.0 0.0 5.5
1 1/4 0.6 0.6 0.3 0.4 1.3 0.6 0.6
16.5 0.0 5.5
1 0.5 0.5 0.2 0.3 1.0 0.5 0.5
Pipe size

13.7 0.0 5.2

3/4 0.4 0.4 0.2 0.3 0.8 0.4 0.4
12.2 0.0 4.6
100 | P a g e

1/2 03 0.3 0.1 0.2 0.6 0.3 0.3

11.6 0.0 4.6
Long radius Branch Regular Long radius
Regular 90° Regular 45° Line flow Globe Gate Angle
90° flow 180° 180°

Flanged
fitting
Elbows Tees Return bends Valves
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(44) Moody chart:

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(45) Water Vapor Pressure:

Temperature (°C) Pressure (kPa)

0 0.6113
5 0.8726
10 1.22
15 1.70
20 2.33
25 3.16
30 4.24
35 5.62
40 7.38
45 9.58
50 12.34
55 15.75
60 19.93
65 25.02
70 31.17
75 38.56
80 47.37
85 57.81
90 70.11
95 84.52
100 101.32
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(46) Pipe fitting:

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(47) K factor:

Surface Absolute Roughness-K

(m) (feet)
Copper, Lead, Brass, 0.001-0.002 3.3-6.7
Aluminum (new)

PVC and Plastic Pipes 0.0015-0.007 0.5-2.33

Epoxy, vinyl ester & 0.005 1.7

isophthalic pipe
Stainless steel 0.015 5
Steel commercial pipe 0.045-0.09 1.5-3

Stretched steel 0.015 5

Weld steel 0.045 1.5
Galvanized steel 0.15 5
Rusted steel 0.15-4 5-133
(corrosion)
New cast iron 0.25-0.8 8-27
Worn cast iron 0.8-1.5 2.7-5
Rusty cast iron 1.5-2.5 5-8.3
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AUTHOR’S UPCOMING BOOKS

 Heat transfer concept & shell & tube heat exchange

design volume 1.
 Engineering thermodynamics concept &
centrifugal/turbo compressor design volume 1.
 Engineering thermodynamics concept & reciprocating &
axial compressor design volume 2.
 Mass transfer concept & distillation column
design/sizing volume 1.
 Mass transfer concept & all types of separators & vessel
design/ sizing volume 2.
 Onshore/offshore engineering concept & offshore
production facilities & structure volume 1.
 Oil & gas (onshore/offshore) engineering concept &
subsea & onshore export pipeline design using pipe SIM
volume 2.
 Oil & gas (onshore/offshore) engineering concept &
flow assurance & transient study using OLGA volume 3.
 Oil & gas (onshore/offshore) engineering concept &
offshore production facilities design, simulation &
modeling using Aspen HYSYS. Volume 4
 Oil & gas (onshore/offshore) engineering concept &
dynamic simulation using Aspen HYSYS.
 Oil & gas (onshore/offshore) engineering concept &
blow down/ depressurization/ PSV sizing relief system
(flare net) design.