Hydraulic Calculations Report

TNPA 714 – Provision of Professional Services to conduct a
detailed design, engineering and feasibility study of the

Dewatering Pump Systems at Robinson and Sturrock Dry
Docks in the Port of Cape Town
Hydraulic Design and Calculation Report
REV: 2
April 2019
Reviewed by:
“Person/s Reviewing the Document” Date
Name:
Position:
Approved by:
“Approver” Date
Name:
Position:
T. Augustyn E. Biesenbach
telez@mne-oak.co.za ewald.biesenbach@aurecongroup.com
PORT OF CAPE TOWN: ROBINSON AND STRUROCK DRY DOCKS: HYDRAULIC CALCULATIONS REPORT
INDEX
Contents
1 INTRODUCTION ............................................................................................................................. 3
2 BASIS OF DESIGNS ....................................................................................................................... 3
2.1 Sturrock Dock .......................................................................................................................... 3
2.1.1 Main Pumps ........................................................................................................................ 3
2.1.2 Drainage Pumps.................................................................................................................. 4
2.1.3 Seepage Pumps .................................................................................................................. 4
2.2 Robinson Dock Pumping Systems .......................................................................................... 4
2.2.1 Main Pumps ........................................................................................................................ 4
2.2.2 Drainage Pumps.................................................................................................................. 5
2.2.3 Seepage Pumps .................................................................................................................. 5
3 DESIGN CALCULATIONS .............................................................................................................. 5
3.1 Formulas ................................................................................................................................. 6
3.2 Sturrock Dock .......................................................................................................................... 8
3.2.1 Main Pumps ........................................................................................................................ 8
3.2.2 Drainage Pumps................................................................................................................ 13
3.2.3 Seepage Pumps ................................................................................................................ 16
3.3 Robinson Dock ...................................................................................................................... 18
3.3.1 Main Pumps ...................................................................................................................... 18
3.3.2 Drainage Pumps................................................................................................................ 21
3.3.3 Seepage Pumps ................................................................................................................ 24
4 CONCLUSIONS ............................................................................................................................. 27
ANNEXURE A ....................................................................................................................................... 28
Sample Calculations - Sturrock Dry Dock Main Pump System ......................................................... 28
ANNEXURE B ....................................................................................................................................... 47
Sturrock Dock Schematic Drawings .................................................................................................. 47
ANNEXURE C ....................................................................................................................................... 53
Robinson Dock Schematic Drawings ................................................................................................ 53
2
1 INTRODUCTION
MNE OAK has been appointed for the FEL3 feasibility study and basic engineering design for the
replacement of the dewatering pump systems at Robinson and Sturrock Dry Docks.
As part of the scope of services and the activity schedule, it is required that the hydraulic design
calculations be reported and submitted in a report format for record purposes.
This report aims to summarise the basis of design used in the hydraulic calculations for the respective
hydraulic pumping systems. It will also include sample calculations for one (1) system, with variables,
assumptions and components indicated for all systems.
In total, the scope of works involves six (6) hydraulic systems as listed below and discussed in this
report:
A. Sturrock Dock
o Main Pumps System
o Drainage Pump System
o Seepage Pump System
B. Robinson Dock Pumping
o Main Pumps System
o Drainage Pump System
o Seepage Pump System
2 BASIS OF DESIGNS
The sub sections below summarise the basis of the design flowrates for each of the respective hydraulic
systems, as presented in the Technical Assessment Report
2.1 Sturrock Dock

The sub sections below summarise the basis of the design flowrates for each of the respective hydraulic
systems, as presented in the Technical Assessment Report
2.1.1 Main Pumps

The purpose of the main pumps is to drain the dock of water once the vessel is inside, as quickly as
possible, in order to get the vessel safely onto the rest blocks.
The estimated Volume of the Robinson Dock is 240 000 m3. The agreed ideal time to drain the dock
with the main pumps is 4 hours. There are currently three (3) main pumps installed. Each pump has its
own dedicated suction and delivery pipework, meaning its own hydraulic system.
This equates to a Main pump system drainage flowrate of 240 000/4 = 60 000 m3/hr average.
If this is split over the 3 installed pumps, the flowrate per pump = 20 000 m3/hr.
Design Flowrate (per pump) - 20 000 m3/hr = 5 560 l/s
There were three (3) further potential design constraints identified, these are:
o The use of the existing discharge culvert and pipe = 1350mm Diameter Nominal Bore
o Using the existing/available space with the pump sump and pump station building. This
includes considerations of pump design/operating requirements, other equipment in the
3
station and Health and Safety requirements. This would determine the number of pumps
used to pump the desired flow rate.
2.1.2 Drainage Pumps

The purpose of the drainage pump/s is to dewater the balance of the dock once the main pumps have
stopped pumping and to manage any leakage and/or cooling system water entering the dock in order
to keep the dock dry.
There were four (4) potential design constraints identified, these are:
o The use of the existing discharge pipe = 450mm Diameter Nominal Bore
o Recommended pipe flow velocity guidelines.
o Dewatering at a minimum rate of 720 m3/hr (200 l/s), being the maximum rate that the
cooling water pumps can deliver at
Considering the above, it was agreed that the drainage pump system be able to pump at a flowrate of
250 l/s based on the maximum safe flow velocity in the pipeline.
Design Flowrate - 250 l/s
Each pump has its own dedicated suction and delivery pipework, meaning its own hydraulic system.
This allows the system to operate together and drain at a total flowrate of 500 l/s if need be.
2.1.3 Seepage Pumps

The purpose of the seepage pump is to drain any minor casual water in the pump station building/room
itself. This water may typically come from leakage through station walls as well as drained water from
equipment when maintenance is performed.
As there was no permanently installed seepage pump, it was agreed that this pumping system be able
to handle a flowrate of 15 l/s based on the maximum safe flow velocity in the pipeline.
2.2 Robinson Dock Pumping Systems
2.2.1 Main Pumps

The purpose of the main pumps is to drain the dock of water once the vessel is inside, as quickly as
possible, in order to get the vessel safely onto the rest blocks.
The estimated Volume of the Robinson Dock is 24 000 m3. The agreed ideal time to drain the dock with
the main pump/s is 4 hours.
This equates to a Main pump system drainage flowrate of 24000/4 = 6000 m 3/hr average.
Design Flowrate - 6000 m3/hr = 1 670 l/s
There were three (3) further potential design constraints identified, these are:
o The use of the existing discharge culvert and pipe = 1000mm Diameter Nominal Bore
4

The purpose of the drainage pump/s is to dewater the balance of the dock once the main pumps have
stopped pumping and to manage any leakage or other water entering the dock in order to keep the
dock dry.
There were three (3) potential design constraints identified, these are:
o The use of the existing discharge pipe = 200mm Diameter Nominal Bore
o Recommended pipe flow velocity guidelines.
Considering the above, it was agreed that the drainage pump system be able to pump at a flowrate of
50 l/s based on the maximum safe flow velocity in the pipeline.
2.2.3 Seepage Pumps

The purpose of the seepage pump is to drain any minor casual water in the pump station building/room
itself. This water may typically come from leakage through station walls as well as drained water from
equipment what maintenance is performed.
As there was no permanently installed seepage pump, it was agreed that this pumping system be able
to handle a flowrate of 6 l/s based on the maximum safe flow velocity in the pipeline.
3 DESIGN CALCULATIONS
This section describes the design formulas used to calculate total pumping head for each pumping of
the six (6) hydraulic pumping systems.
This actual process for calculating total head for each done using a hydraulic simulation design tool.
For purposes of this report, we have manually conducted the calculations for one system, namely,
Sturrock Dry Dock – Main pumps. This is included as an example in Annexure A.
All relative components, variables and assumptions used for the calculation of the total head in each
system, will be provided in each sub section along with the answers obtained using the hydraulic
simulation design tool.
It must be noted that this is an iterative process and final simulations will be conducted again, based on
the final detail designs of the systems. These first-round iteration calculations were done on the existing
equipment sizes and shall be reiterated once the final designs are completed and new equipment sizes
are confirmed. This final iteration calculation information will be used in the FEL 3 Tender Package as
the specification requirements.
5
3.1 Formulas
The following formulas are relevant and were used in the calculations:
Total Head
Total Head (HT) = Hs(Static) + Hf (Friction) + Hm(minor or shock losses)
Frictional Loss in Circular Pipes: Hazen Williams
Where: Hf = Friction Loss [m]

L = Pipe Length (m)
C = Coefficient of Friction - Hazen Williams Table)
d = Diameter of Pipe [m]
Q = flow rate [m3/s]
Shock/Minor Losses in Fittings

Hm = (#KV2) / 2g
Where: Hm = Shock Loss [m]

# = Quantity of Fittings
V = Water/Flow velocity [m/s]
g = Gravitational Constant = 9.81 m/s2
Flow Velocity
V = Q/A
Where: V = Water/Flow velocity [m/s]

Q = flow rate [m3/s]
A = Cross Sectional Area [m2]
Area of a Circle/Pipe
A = πD2/4
6
Where: D = Diameter of Pipe [m]

π = Pi / Constant = 3.142
A = Cross Sectional Area [m2]
Water Power
P = ρ.g.Q.h/1000
Where: P = Water Power [kW]

ρ = density of water [kg/m3]
g = gravity [m/s2]
Q = flow capacity [m3/s]
h = pump head [m]
Shaft Power
Ps = P / η
Where: Ps = Shaft Power [kW]

Pw = Water Power [kW]
η = pump efficiency
Absorbed Power
Pa = Ps / η
Where: Pa = Absorbed Power [kW]
Ps = Shaft Power [kW]
η = motor efficiency
Notes:
Hs
This is the static Water Level Height difference in a given system.
Minimum Hs would typically be when the dock is full or water level in the suction side is at its highest
and discharge level/sea level is at its lowest
Maximum Hs would typically be when dock is empty or at the suggested pump stop level and the
discharge level/sea is at its highest level (HWL).
Hf
This is the sum of all frictional losses in all pipe lengths/components of the given hydraulic system. This
includes suction and delivery pipe lengths. The is calculated using Hazen Williams Theory/Formula,
with respective C Values as per the formula above. It is general practice that a factor of safety be added
7
to this to cover the unknowns or any assumptions made that could be incorrect. In our case, we used a
Factor of Safety of 15%.
Hm
This is the sum of all minor or shock losses in a given hydraulic system. These losses include, but not
limited to items such as valves, exits/entries, reducers, etc. It is general practice that a factor of safety
be added to this to cover the unknowns or any assumptions made that could be incorrect. In our case,
we used a Factor of Safety of 15%.
3.2 Sturrock Dock
3.2.1 Main Pumps

The all applicable calculations, references and total thought train can be seen in the manual long
handed calculations of this system shown in Annexure A.
For purposes or of uniformity, we summarise the data used/inputted, and assumptions made below.
Hs – Calculations
Refer applicable levels used for this system in blue on Sturrock Dry Dock Level Schematic Drawing
attached in Annexure B.
Minimum Static Head – HSmin = 2.02m – 0.00m = -2.02m
Maximum Static Head – HSmax = 2.02m – (-12.00m) = 14.00m
Hf – Calculations
Refer applicable pipe lengths used for this system in blue, denoted as 1, 2, 3, etc. on Sturrock Dry Dock
Level Schematic and/or the Process Flow Diagram drawings attached in Annexure B.
Hf1 Calculation – Suction Culvert between Dock and Pump Sump
Assumptions/Data Used:
L = 160m (Worst Case when inner dock is dewatered only)
D = 2600mm (for purposes of round pipe)
Actual is rectangular with cross section area of 2.763m x 2.584m = 7.07 m2
Worst-case cross section area is Circle = 5.31m 2
Q = 16 670 l/s or 16.67 m3/s (All three pumps running – 3 x 5 557 l/s)
C = 80 for concrete or asbestos cement pipe older than 50 years/badly corroded. Assumed worst case.
Based on Calculations, as shown, Hf1 = 0.89m
Hf2 Calculation – Suction Pipework between Main Pump Sump and Pump
L = 10m maximum suction pipe length
D = 1500mm Nominal Bore (60” given on as-built drawings)
Q = 5 550 l/s or 5.55 m3/s
8
C = 80 for Steel pipe older than 50 years/badly corroded. Assumed worst case.
Hf3 Calculation – Delivery Pipework between Pump and Discharge into Sea
L = 10m maximum delivery pipe length
D = 1350mm Nominal Bore, (Exact Internal Diameter is unknown)
Worst case as delivery culvert enlarges in a taper like construction to a discharge point of +-
2600mm in diameter.
Q = 5 550 l/s or 5.55 m3/s
C = 80 for Steel pipe older than 50 years/badly corroded. Assumed worst case.
Hf Total Calculation
Hf Total = Hf1 + Hf2 + Hf3

= 0.89 + 0.093 + 0.15
= 1.133m
Adding 15% FOS Hf Total = 1.30m
Hm - Calculations
Refer applicable shock loss fittings used for this system in blue, denoted as A, B, C, etc. on the Process
Flow Diagram drawings attached in Annexure B.
HmA Calculation – Outlet of Dock

Any Outlet Strainer/grating is ignored.
Worst Case Scenario – Only 1 outlet is used as if Inner or Outer Dock is dewatered only.
D = 2600mm
Actual is rectangular with cross section area of 2.763m x 2.584m = 7.07 m 2
Worst-case cross section area is Circle = 5.31m 2
K=1
g = 9.81 m/s2
Based on Calculations, as shown, HmA = 0.50m
9
HmB Calculation – Isolating Valve “E”

Worst Case Scenario – Only 1 outlet is used as if Inner or Outer Dock is dewatered only, using Valve
“E” only.
D = 2100mm
K = 0.25
g = 9.81 m/s2
Based on Calculations, as shown, HmB = 0.30m
HmC Calculation – Reducers before and after Valve “E”

Worst Case Scenario – Only 1 outlet is used as if Inner or Outer Dock is dewatered only, using Valve
“E” only.
D = 2100mm
K = 0.3 (0.1 to 0.5 could be used subject to reducer angle)
#=2
g = 9.81 m/s2
Based on Calculations, as shown, HmC = 0.36m
HmD Calculation – Pump Suction Reducer

D = 1500mm
Q = 5 550 l/s or 5.550 m3/s (Applicable for 1 pump running)
K = 0.3 (0.1 to 0.5 could be used subject to reducer angle)
#=1
g = 9.81 m/s2
Based on Calculations, as shown, HmD = 0.15m
HmE Calculation – 90 Degree Bend in Suction Pipe

D = 1500mm
K = 0.75
#=1
g = 9.81 m/s2
10
Based on Calculations, as shown, HmE = 0.38m
HmF Calculation – Suction Isolating Valve “1S”

D = 1500mm
K = 0.25
#=1
g = 9.81 m/s2
Based on Calculations, as shown, HmF = 0.13m
HmG Calculation – Delivery Isolating Valves “1D” and “F”

D = 1350mm
K = 0.25
#=2
g = 9.81 m/s2
Based on Calculations, as shown, HmG = 0.38m
HmH Calculation – Discharge Outlet into Sea

Any Discharge Strainer/grating is ignored.
D = 2600mm
K=1
#=1
g = 9.81 m/s2
Based on Calculations, as shown, HmG = 0.06m
Hm Total Calculation
Hm Total = HmA + HmB + HmC + HmD + HmE + HmF + HmG + HmH

= 0.50 + 0.30 + 0.36 + 0.15 + 0.38 + 0.13 + 0.38 + 0.06
= 2.26m
11
Adding 15% FOS Hm Total = 2.60m
Total Maximum Head Calculations

= 14.00m + 1.30m + 2.6m
= 17.9m
Maximum Water Power Calculations

Q = 5 550 l/s or 5.550 m3/s (Nominal/Designed Flowrate)
Max Head = 17.9m
g = 9.81 m/s2
Using the Formula provided, we calculate the maximum water power to be 975kW.
This is based on designed flowrate and at maximum head.
Maximum Absorbed/Shaft Power Calculations – Theoretical

Assumptions – Pump Efficiency of 75%.
Using the Formula provided, we calculate the maximum theoretical shaft power (Ps) to be 1300kW per
pump.
Maximum Water Power and Absorbed/Shaft Power Calculations – Actual

In our case, it was agreed that the designed flowrate, i.e. 5550l/s is the maximum flow to be used, which
will typically be experienced at “Dock Full” level or scenario, due to the flow velocity through delivery
pipe fittings at this flowrate. In addition, in accordance with pump curves, this flowrate will decrease as
the dock empties and the pumping head increases, implying that flow implying the following average
power calculations:
Q = 4200 l/s or 4.20 m3/s (Nominal/Designed Flowrate)
Max Head = 16m
g = 9.81 m/s2
Pump Efficiency of 75%.
Using the Formula provided, we calculate the maximum water power to be 660kW.
Using the Formula provided, we calculate the maximum average shaft pump power (Ps) to be 880kW.
12

Hs – Calculations
Refer applicable levels used for this system in green on Sturrock Dry Dock Level Schematic Drawing
attached in Annexure B.
Minimum Static Head – HSmin = 3.53m – (-12.00m) = 15.53m
Hf – Calculations
Refer applicable pipe lengths used for this system in green, denoted as 1, 2, 3, etc. on Sturrock Dry
Dock Level Schematic and/or the Process Flow Diagram drawings attached in Annexure B.
Hf1 Calculation – Drainage Pump Suction Pipe between sump and pump
L = 10m
D = 500mm
Q = 250 l/s or 0.25 m3/s
C = 100 for Steel pipe older than 50 years/badly corroded.
Hf2 Calculation – Delivery Pipework between Pump and discharge point

L = 30m
D = 450mm
Q = 250 l/s or 0.25 m3/s
Hf Total = Hf1 + Hf2
= 0.05 + 0.24
= 0.29m
13
Hm - Calculations
Refer applicable shock loss fittings used for this system in green, denoted as A, B, C, etc. on the
Process Flow Diagram drawings attached in Annexure B.
HmA Calculation – Pump Suction Reducer
D = 500mm
Q = 250 l/s or 0.25 m3/s
K = 0.1
g = 9.81 m/s2
HmB Calculation – 90 Degree Bend in Suction Pipe

D = 500mm
Q = 250 l/s or 0.25 m3/s
K = 0.75
g = 9.81 m/s2
HmC Calculation – Suction Isolating Valve “4S”

D = 500mm
Q = 250 l/s or 0.25 m3/s
K = 0.25
g = 9.81 m/s2
HmD Calculation – Delivery Isolating Valve “4D”

D = 450mm
Q = 250 l/s or 0.25 m3/s
K = 0.25
g = 9.81 m/s2
14
HmE Calculation – 90 Degree Bends in Delivery Pipe

D = 450mm
Q = 250 l/s or 0.25 m3/s
K = 0.75
#=4
g = 9.81 m/s2
HmF Calculation – Delivery Non-Return Valves

D = 450mm
Q = 250 l/s or 0.25 m3/s
K = 0.35
#=2
g = 9.81 m/s2
Based on Calculations, as shown, HmF = 0.09m
Hm Total = HmA + HmB + HmC + HmD + HmE + HmF

= 0.01 + 0.06 + 0.02 + 0.03 + 0.38 + 0.09
= 0.59m

= 23.93m + 0.33m + 0.68m
= 24.94m
Max Head = 24.94m
g = 9.81 m/s2
Using the Formula provided, we calculate the maximum water power to be 61.2kW.
15

Using the Formula provided, we calculate the maximum theoretical shaft pump power (Ps) to be 82kW.
3.2.3 Seepage Pumps

Hs – Calculations
Refer applicable levels used for this system in red on Sturrock Dry Dock Level Schematic Drawing
attached in Annexure B
Hf – Calculations
Refer applicable pipe lengths used for this system in red, denoted as 1, 2, 3, etc. on Sturrock Dry Dock
Level Schematic drawing attached in Annexure B.
Hf1 Calculation – Discharge Pipe between pump and discharge point
L = 40m
D = 100mm
Q = 15 l/s or 0.015 m3/s
Hf Total = Hf1
= 2.62m
Hm - Calculations
Refer applicable shock loss fittings used for this system in red, denoted as A, B, C, etc. on the Sturrock
Dry Dock Level Schematic drawing attached in Annexure B.
HmA Calculation – Delivery Non-Return Valve
D = 100mm
Q = 15 l/s or 0.015 m3/s
#=2
16
K = 0.35
g = 9.81 m/s2
HmB Calculation – Delivery Isolating Valve

D = 100mm
Q = 15 l/s or 0.015 m3/s
#=1
K = 0.25
g = 9.81 m/s2
HmC Calculation – Delivery 90 Degree Bends

D = 100mm
Q = 15 l/s or 0.015 m3/s
#=5
K = 0.75
g = 9.81 m/s2
HmD Calculation – Delivery Discharge Point

D = 100mm
Q = 15 l/s or 0.015 m3/s
#=1
K=1
g = 9.81 m/s2
Hm Total = HmA + HmB + HmC + HmD

= 0.13 + 0.05 + 0.70 + 0.19
= 1.07m
17

= 19.53m + 3.00m + 1.23m
= 23.76m
Max Head = 23.76m
g = 9.81 m/s2

Assumptions – Pump Efficiency of 50%. Drainage Submersible pumps generally have a much lower
efficiency
Using the Formula provided, we calculate the maximum theoretical shaft pump power to be 7kW.
3.3 Robinson Dock
3.3.1 Main Pumps
Hs – Calculations
Refer applicable levels used for this system in blue on Robinson Dry Dock Level Schematic Drawing
attached in Annexure C
Minimum Static Head – HSmin = 0.62m – 2.02m = -1.40m
Hf – Calculations
Refer applicable pipe lengths used for this system in blue, denoted as 1, 2, 3, etc. on Robinson Dry
Dock Level Schematic and/or the Process Flow Diagram drawings attached in Annexure C.
Refer applicable pipe lengths used for this system in red, denoted as 1, 2, 3, etc. on Sturrock Dry Dock
Level Schematic drawing attached in Annexure B.
Hf1 Calculation – Main Pump Suction Pipe between sump and pump
18
Frictional loss in suction culvert is ignored.

L = 10m
D = 1000mm
Q = 1670 l/s or 1.670 m3/s
C = 150 for New Steel pipe (Assuming New Steel Suction pipe)
Hf2 Calculation – Delivery Pipe pump and discharge point

Assumed that delivery pipe spans the length of the discharge culvert (Worst Case)
L = 50m
D = 1000mm
Q = 1670 l/s or 1.670 m3/s
= 0.3m
Hm - Calculations
Refer applicable shock loss fittings used for this system in blue, denoted as A, B, C, etc. on the Robinson
Dry Dock Process Flow Diagram drawings attached in Annexure C.
D = 900mm
Q = 1670 l/s or 1.670 m3/s
#=1
K = 0.35
g = 9.81 m/s2

D = 900mm
19
Q = 1670 l/s or 1.670 m3/s

#=1
K = 0.25
g = 9.81 m/s2

D = 900mm
Q = 1670 l/s or 1.670 m3/s
#=2
K = 0.75
g = 9.81 m/s2

D = 1000mm
Q = 1670 l/s or 1.670 m3/s
#=1
K=1
g = 9.81 m/s2

= 0.12 + 0.09 + 0.53 + 0.23
= 0.97m

= 9.65m + 0.35m + 1.12m
= 11.12m
20

Max Head = 11.12m
g = 9.81 m/s2

Using the Formula provided, we calculate the maximum theoretical shaft pump power (Ps) to be 243kW.

Hs – Calculations
Refer applicable levels used for this system in green on Robinson Dry Dock Level Schematic Drawing
Hf – Calculations
Refer applicable pipe lengths used for this system in green, denoted as 1, 2, 3, etc. on Robinson Dry
Dock Level Schematic and/or the Process Flow Diagram drawings attached in Annexure C.
Hf1 Calculation – Suction Pipe Between sump and Pump Suction
Frictional loss in suction culvert is ignored.
L = 12m
D = 200mm
Q = 50 l/s or 0.050 m3/s
Hf2 Calculation – Delivery Pipe between pump and discharge point

Assumed that delivery pipe spans the length of the discharge culvert (Worst Case)
L = 50m
D = 200mm
21
Q = 50 l/s or 0.050 m3/s

= 1.29m
Hm - Calculations
Refer applicable shock loss fittings used for this system in green, denoted as A, B, C, etc. on the
Robinson Dry Dock Process Flow Diagram drawings attached in Annexure C.
HmA Calculation – Suction Inlet
Inlet Loss is worse than reducer (Worst Case)
D = 200mm
Q = 50 l/s or 0.050 m3/s
#=1
K=1
g = 9.81 m/s2

D = 200mm
Q = 50 l/s or 0.050 m3/s
#=1
K = 0.25
g = 9.81 m/s2
HmC Calculation – Delivery Non-Return Valve

D = 200mm
Q = 50 l/s or 0.050 m3/s
22
K = 0.35
g = 9.81 m/s2
HmD Calculation – Delivery 90 Degree Bends

D = 200mm
Q = 50 l/s or 0.050 m3/s
#=2
K = 0.75
g = 9.81 m/s2
HmE Calculation – Delivery Discharge Point

D = 200mm
Q = 50 l/s or 0.050 m3/s
#=1
K=1
g = 9.81 m/s2
Hm Total = HmA + HmB + HmC + HmD + HmE

= 0.13 + 0.03 + 0.05 + 0.19 + 0.13
= 0.53m

= 11.02m + 1.48m + 0.61m
= 13.11m

23

Max Head = 13.11m
g = 9.81 m/s2

Using the Formula provided, we calculate the maximum theoretical shaft pump power (Ps) to be 8.6kW.
3.3.3 Seepage Pumps
Hs – Calculations
Refer applicable levels used for this system in red on Robinson Dry Dock Level Schematic Drawing
It is assumed that the discharge level is just below ground. This must be finalised.
Hf – Calculations
Refer applicable pipe lengths used for this system in red, denoted as 1, 2, 3, etc. on Robinson Dry Dock
Level Schematic and/or the Process Flow Diagram drawings attached in Annexure C.
Hf1 Calculation – Discharge Pipe between pump and discharge point
L = 40m (Worst Case assumption and must be finalised)
D = 80mm
Q = 6 l/s or 0.006 m3/s
C = 150 for New Steel pipe (Assuming New Steel delivery pipe)
Hf Total = Hf1
= 0.67m
24
Hm - Calculations
Refer applicable shock loss fittings used for this system in red, denoted as A, B, C, etc. on the Robinson
Dry Dock Process Flow Diagram drawings attached in Annexure C.
D = 80mm
Q = 6 l/s or 0.006 m3/s
#=1
K = 0.35
g = 9.81 m/s2

D = 80mm
Q = 6 l/s or 0.006 m3/s
#=1
K = 0.25
g = 9.81 m/s2

D = 80mm
#=4
K = 0.75
g = 9.81 m/s2

D = 80mm
Q = 6 l/s or 0.006 m3/s
#=1
K=1
g = 9.81 m/s2
25

= 0.03 + 0.02 + 0.22 + 0.07
= 0.34m

= 6.80m + 0.77m + 0.39m
= 7.96m

Max Head = 7.96m
g = 9.81 m/s2

Assumptions – Pump Efficiency of 50%. Drainage Submersible pumps generally have a much lower
efficiency
Using the Formula provided, we calculate the maximum theoretical shaft pump power (Ps) to be 1.0kW.
26
4 CONCLUSIONS
It is hoped that this report adequately fulfils the Hydraulic Calculations requirements.
These hydraulic simulation calculations of each system must be re iterated with the final system design
information and components before final pump duties and operating parameter requirements are
entered in the specifications of the FEL3 Study tender document.
27
ANNEXURE A
Sample Calculations - Sturrock Dry Dock Main Pump System
28
ANNEXURE B
Sturrock Dock Schematic Drawings

The following drawings are included:
Main Pumps Level/Section Schematic Drawing

Main Pumps Plan Schematic Drawing
Drainage Pumps Level/Section Schematic Drawing
Drainage Pumps Plan Schematic Drawing
Seepage Pumps Level/Section Schematic Drawing
47
48
49
50
51
52
ANNEXURE C
Robinson Dock Schematic Drawings

The following drawings are included:
Main Pumps Level/Section Schematic Drawing

Main Pumps Plan Schematic Drawing
Drainage Pumps Level/Section Schematic Drawing
Drainage Pumps Plan Schematic Drawing
Seepage Pumps Level/Section Schematic Drawing
53
54
55
56
57
58

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TNPA 714 – Provision of Professional Services to conduct a

detailed design, engineering and feasibility study of the

2.1 Sturrock Dock

2.1.1 Main Pumps

2.1.2 Drainage Pumps

2.1.3 Seepage Pumps

2.2 Robinson Dock Pumping Systems

2.2.1 Main Pumps

2.2.2 Drainage Pumps

2.2.3 Seepage Pumps

Total Head (HT) = Hs(Static) + Hf (Friction) + Hm(minor or shock losses)

Frictional Loss in Circular Pipes: Hazen Williams

Where: Hf = Friction Loss [m]

Shock/Minor Losses in Fittings

Where: Hm = Shock Loss [m]

Where: V = Water/Flow velocity [m/s]

Where: D = Diameter of Pipe [m]

Where: P = Water Power [kW]

Where: Ps = Shaft Power [kW]

3.2 Sturrock Dock

3.2.1 Main Pumps

Hf Total = Hf1 + Hf2 + Hf3

HmA Calculation – Outlet of Dock

HmB Calculation – Isolating Valve “E”

HmC Calculation – Reducers before and after Valve “E”

HmD Calculation – Pump Suction Reducer

HmE Calculation – 90 Degree Bend in Suction Pipe

Based on Calculations, as shown, HmE = 0.38m

HmF Calculation – Suction Isolating Valve “1S”

HmG Calculation – Delivery Isolating Valves “1D” and “F”

HmH Calculation – Discharge Outlet into Sea

Hm Total = HmA + HmB + HmC + HmD + HmE + HmF + HmG + HmH

Adding 15% FOS Hm Total = 2.60m

Total Maximum Head Calculations

Maximum Water Power Calculations

Maximum Absorbed/Shaft Power Calculations – Theoretical

Maximum Water Power and Absorbed/Shaft Power Calculations – Actual

3.2.2 Drainage Pumps

Hf2 Calculation – Delivery Pipework between Pump and discharge point

HmB Calculation – 90 Degree Bend in Suction Pipe

HmC Calculation – Suction Isolating Valve “4S”

HmD Calculation – Delivery Isolating Valve “4D”

HmE Calculation – 90 Degree Bends in Delivery Pipe

HmF Calculation – Delivery Non-Return Valves

Hm Total = HmA + HmB + HmC + HmD + HmE + HmF

Total Maximum Head Calculations

This is based on designed flowrate and at maximum head.

Maximum Absorbed/Shaft Power Calculations – Theoretical

3.2.3 Seepage Pumps

HmB Calculation – Delivery Isolating Valve

HmC Calculation – Delivery 90 Degree Bends

HmD Calculation – Delivery Discharge Point

Hm Total = HmA + HmB + HmC + HmD

Adding 15% FOS Hm Total = 1.23m

Total Maximum Head Calculations

Maximum Absorbed/Shaft Power Calculations – Theoretical

3.3 Robinson Dock

3.3.1 Main Pumps

Frictional loss in suction culvert is ignored.

Hf2 Calculation – Delivery Pipe pump and discharge point

HmB Calculation – Delivery Isolating Valve

Q = 1670 l/s or 1.670 m3/s

HmC Calculation – Delivery 90 Degree Bends

HmD Calculation – Delivery Discharge Point