Fluid Movement and Work Machines 2017

Equipment fluid movement, work
on fluids, fluids that produce work
Towler ch. 5(?)
1
2013-2017, George T. Dalakos Process Design
3/1/17
Pump power calculations
Need pump power to move fluids:
1. Against friction losses in pipes
2. Up to higher elevation
3. Into a higher pressure vessel
4. Against losses in process units (heat
exchangers, packed bed) or piping misc
(turns, elbows, valves, etc)
2
3/1/17
So, how can you minimize work done
on the fluid? Use common sense
True/False:
Reduce the roughness in the pipe
Increase height to pumping destination
Reduce length of pipe
Increase fluid velocity
Which one is the best way?
3
3/1/17
Work equation talk about machines
that do work
For pumps, work going in will be negative, so
think carefully if the term is positive or negative

(compressible fluids, isentropic)
Negative work input (example: pumps,

compressors )
Positive work output (example: turbine)
4
2013-2017, George T. Dalakos Process
ProcessDesign
Design
3/1/17

Units
Pressure in N/m2head of pressure in m
1N = J/m
Joule is energy unit
Work eqn terms is in J/kg (energy per unit wt.)
Power is J/secrequired or produced (usually in
kW)work on massmultiply by mass rate, kg s-
1
Energy is Power x time. kW x hr or simply, kWhr
(electrical) energy is what we pay $ for ($/kWhr)
5
3/1/17
Friction losses Fluid density
Pipe length
Fluid velocity
Friction factor Pipe inner diam
Moody diagram plots out friction factor as a

function of the Re#
Within the plot, you can see refer to iso-roughness
lines as a ratio of roughness to inner diameter.
Page 247 in Towler has a version of it.
6
3/1/17
7
ProcessDesign
Design
3/1/17
More stuff on piping
Velocity head: Turns, bends, valves

Include into pipe friction losses.
8
3/1/17
Pressure loss in
pipe fittings and
valves
These are dimensionless numbers
Sum all components up
Multiply by velocity head
Simply add this number to the
calculated friction factor
Velocity head (N/m2)

http://www.pipeflow.com/pipe-pressure-drop-calculations/pipe-fitting-loss-calculation
9
ProcessDesign
Design
3/1/17
How Do We Get Fluid From A to B?
A Stabilizer
Column
p = 40 psi
Bottoms Tank
Static
Feed
Head
= 20 psig
B
Cooling Water
2007 G.P. Towler / UOP. For educational use in conjunction with

Sinnott & Towler Chemical Engineering Design only. Do not copy
Chemical Engineering Design
A Stabilizer
Column
p = 40 psi
Feed-Bottoms
Exchanger Bottoms Tank
P = 10 psi
PF = 12 psi p = ?
Static
Feed
PF = 10 psi
Head
= 20 psig
B
Cooling Water
Bottoms
Cooler
P = 10 psi
We need to overcome frictional pressure losses in the piping and

equipment and the static back-pressure in the product tank
We also need to provide enough pressure drop to control the flow with a
control valve

A Stabilizer
Column
How do we get a
p = 40 psi
-20psi across CV?
Feed-Bottoms
P = 10 psi
PF = 12 psi p = ?
Static
Feed
PF = 10 psi
Head
= 20 psig
B
Cooling Water
Bottoms
Cooler
P = 10 psi
Pressure at CV = 40 10 12 10 10 = -2 psi !?!
p across CV = +22 psi?!?

A Stabilizer
Column
p = 40 psi
Feed-Bottoms
P = 10 psi
PF = 12 psi p = 20 psi
Static
Feed
PF = 10 psi
Head
= 20 psig
B
Cooling Water
Bottoms
Cooler
P = 10 psi
No! We add a pump and raise the pressure so that we have the right
pressure gradient across the CV
If we design the pump to deliver a p of 42 psi then we have a battery
limits pressure of 40 psi at the CV and the system is operable

Hydraulic Design
We need to understand the hydraulic flow path to determine pressure
drop, and hence size pumps & compressors
Pumps are cheap, but compressors can be very expensive
In detailed design, we calculate pressure drop for each pipe run &
piece of equipment
In early stages of design we typically calculate p for major
equipment and leave allowances for pipe pressure drop
Pipe diameters are optimized to balance p vs. pipe cost

Optimal Pipe Velocity
1 ft/s = 0.3048 m/s 1 m/s = 3.3 ft/s
Velocity in ft/s:
V = 0.41*gal/min = 0.012*bbl/day
d2 d2
where d is pipe diameter in inches
Suggested pipe velocities (ft/s):

gas: 60 100
liq: 6
superheated steam: 150
Rule of thumb for liquids:

Optimum diameter in inches = (flow in gpm/10)

Example: Feed Pump to Reactor Circuit
PT=200 psig
Plosses = 100 psi
P=10
SEP
P=5 P=5 P=5
P=5 P=5 P=5

P=? P=25
P in =15psig
What is the pressure delivered by the pump? Assume

30psi across control valve

Detailed pressure drops
If you are going to calculate actual pressure drops, focus
on unit operations
For example, long tortuous paths within the unit op is a
good opportunity to spend the extra time figuring out a
realistic pressure drop.
This is especially useful if you think you would like to
optimize the parameters for performance (and cost)
Example: Ergun equation (kinetics, residence time,
packing bed material, catalyst type, cost)

What is a Valve?
A mechanical device to control the flow of a fluid in a
piping system.
Starting and stopping flow
Regulating (throttling) flow volume
Preventing reverse flow
Changing flow direction
Limiting fluid pressure
Isolation of flow
Valves work by restricting or blocking the fluid flow path

Valve Manufacturers Association has a North American
Valve Catalog that lists who makes which kind of valve
(www.VMA.org)
Isolation Valves: Gate Valves
Gate valves are
used for on-off
applications.
Gate valves are best
for infrequent
operation, and when
minimum pressure
drop is needed.
It usually takes
many turns of the
Source: United Valve, www.UnitedValve.com handwheel to open
or close the valve.
Gate Valve Internals
Fluid passes straight through
Stem the valve, minimizing p
Handle
A wedge slides up and down
perpendicular to the flow to
open or close the flow path.
Bonnet
If operated partially open then
Seals seals may become deformed &
Wedge valve may not seat properly
Body
Source: Valve Manufacturers Association, www.vma.org Shell = body + bonnet

Trim = internal components
Isolation Valves: Ball Valves
Stem
Seals
Ball
Body
Source: Valve Manufacturers Association, www.vma.org
Flow path is straight through
A quarter turn is enough to close the valve, therefore quick on/off valve
Isolation Valves: Butterfly Valves
Also quarter turn, therefore quick
Not for complete shut-off, so a blind

flange or back-up valve is needed

Isolation Valves: Plug Valves
The closure element is a
plug with a hole in it.
The plug sits in an
elastomeric sleeve.
Quarter turn operation
Good when tight seal is
required
The sleeve acts as lubricant.
Seat Limited to < 450F due to

Elastomeric liner
Source: United Valve, elastomeric sleeve
www.UnitedValve.com
Source: Valve Manufacturers All metal (metal seated) plug
Association, www.vma.org
valves are also available

Throttling Valves: Globe Valves
Masoneilan 41005 Control Valve Source: Valve Manufacturers

Source: Dresser Inc., www.Dresser.com Association, www.vma.org
Used for throttling (controlling) flow

Can be manual or automatically adjusted
The fluid goes through two 90 changes in flow direction, hence higher
p
Globe Valve Internals
Gap between disk & seat is
Handle
variable orifice to regulate flow
Should not be used <10% open
(causes vibration, noise and
Disk Stem damage to disc & seat)
Bonnet Angle valve = similar design,
but with only one 90 turn
Gasket
Seat
Body

Throttling Valves: Needle Valves
Similar operation to
Handle globe valve, but conical
section machined onto
stem (instead of disk)
and conical seat
Bonnet Used for high accuracy,
Stem low flow services, e.g.
sampling valves
Seat
Body

Control Valves
Usually a globe valve
Actuator with a compressed air
or electric actuator
Actuator adjusts valve
in response to signal
from controlling
instrument (see later
lecture)
Valve

Non Return: Check Valves
Prevent reverse flow, e.g. at
pump or compressor discharge,
pipe headers
Main types are
Swing
Lift
Wafer

Check Valves
Swing check valve is most common in liquid
service. The flow swings the disc upward,
opening the valve. If flow stops, the weight
of the disc returns it to the seat.
Swing valve is not good in pulsing flow, for
slurries or gases or for high velocity flows
Wafer valve requires less p to open & is
smaller & cheaper, but restricted to
velocities in range 3-11 ft/s
Check valve installation: make sure gravity
is going the direction you want!
Source: Tyco Flow Control

www.tycoflowcontrol-na.com/brands_results.asp?Selection=Prince

Centrifugal Pump
Discharge
Suction
Shaft
Source: UOP
Impeller
Most common type of pump for liquid service
Rotating shaft spins impeller, fluid enters at center and is discharged

at wall
Shaft can be driven by motor, turbine

Pump Impellers
Open Partially Open Enclose
Source: UOP
Most casings can handle a range of impeller size as well as different

types of impeller
Hence can get different performance characteristics with the same
casing and motor

Pump Performance Curves
A given impeller
diameter and speed
defines a head-capacity
Total Differential Head in Feet
curve
550 11" Dia.
500 The pump always
450 10" operates on this curve,
400 regardless of fluid, inlet
350 9" pressure
300
250 Head in feet
200
= (P2-P1)(psi) (2.31)/S.G.
Head in meters
0 400 800 1200 1600 2000 2400 = (P2-P1)(bar) (10.2)/S.G.

Gallons Per Minute
Identical Pumps Handling Liquids
of Different Specific Gravity
100 ft. 100 ft. 100 ft.
32.5 psi 43 psi 52

psi
Gasoline, S.G. = 0.75 Water, S.G. = 1.0 Brine, S.G. = 1.2
Discharge pressure:
100 x 0.75 100 x 1.0 100 x 1.2
= 32.5 psi = 43 psi = 52psi
2.31 2.31 2.31
ote: head is same even though density is different

Make sure inlet
Pressure > Net
positive suction head
(NPSH)
Pump Efficiency
60 The pump curve also
40
20 NPSH
shows the pump
0
efficiency, which is also a
550 11" Dia. strong function of flow
Total Differential Head In Feet
40 50
500 60 65
70 74 rate
450 76 78 BEP
10" 80%
400 The Best Efficiency Point
80
350 9" 78 for each impeller is
300
250
76
74
sometimes indicated
200 70
Some pump curves also
show bhp requirements,
but note that this is for
0 400 800 1200 1600 2000 2400 s.g. = 1, so it is best to
Gallons Per Minute calculate this
Two Centrifugal Pumps in Parallel
150
100
Head (Ft)
Combined Curve
50
Pump B Pump A
0
0 400 800 1200 1600 2000 2400
Capacity (gpm)
More flow, but never more head

Two Centrifugal Pumps in Series
250
200
Combined Curve
Head Ft.
150
Pump A
100
50
Pump B
0
0 400 800 1200 1600 20000
Capacity gpm
Typical Motor/Motor Spare Pump
Arrangement
Discharge Rotating equipment
usually has lower
reliability than other
Open
equipment
PI PI Pumps are relatively
M P1 M cheap, so almost always
have a spare pump in line
Open Usually specify 3 or 4
pumps per service
Suction 1 running
1 waiting
1 in the shop
1 on the shelf

Efficiency of pumps, compressors
and turbines
Actual power required (W = negative)
Actual power produced (W = positive)

Start withIf I am 50% efficient, then I require/produce 50% more/less power
***design: if supplying energy to a required unit operation (supplying to), may
want to over-rate by 10% or more for flexibility, system degradation, misc at
max flow conditions
38
3/1/17
Pump Work
Hydraulic hp = liq flow (lb/min) x head (ft)
33,000
Brake hp = hydraulic hp / efficiency
= gpm x head (psi)
1750 x efficiency
Metric units:
Power delivered (W) = flow (m3s-1) x p (Nm-2)
Shaftwork required = power delivered / efficiency

Example: Feed Pump to Reactor Circuit
PT=200 psig
Plosses = 100 psi
P=10
SEP
P=5 P=5 P=5
P=5 P=5 P=5

P=? P=25
P in =15psig
1hp = 745.6W
Assume $0.1/kWhr & continuous running
If the flow rate is 300gpm & the pump efficiency is 60%, what is the
motor duty in hp? In kW?
How much to run this pump for one year?
Gas Compression
m
T1, p1 T2, p2
Adiabatic compression: w
k 1 /k
T2 p (p V k = constant)
2 k = Cp/Cv = 1.4 for diatomic gases
T1 p1
Compressor work:
k 1 /k
k m R T1 p 2
w ad,kW 1 m [kg/s], R [J/kg.K], T [K]
k 1 9806 p1

k 1 /k
k m R T1 p 2
w ad,hp 1 m [lb/s], R [ft.lbf/lb.R], T [R]
k 1 550 p1

Actual compressor work:
w ad
w
compressor efficiency ,
Types of Compressors
Compressors
Dynamic Positive Displacement
Radial Flow Axial Flow Rotary Reciprocating

(Centrifugal)
Single Rotor Two Rotor
Sliding Vane Liquid Ring Roots Screw

Ranges of Application
for Most Common Compressors
105
Discharge Pressure, psia
104
Reciprocating
103
Centrifugal
102
Axial
Flow
10
10 102 103 104 105 106

Inlet flow, ACFM
Centrifugal Compressors
Source: Howden Buffalo Inc.,

www.howdenbuffalo.com

Centrifugal Compressor Impeller & Cover
Source: Dresser Inc., www.Dresser.com
Source: Howden Buffalo Inc..,

www.howdenbuffalo.com

8-Stage Centrifugal Compressor

Axial Compressors
Flow passes
between rotating
and stationary
vanes along axis
of compressor
Basically the
same as the front
end of a jet
engine

Reciprocating Compressor
Piston Rod Crank
Head End
Rod Connecting
Packing Rod
Crosshead Crosshead
Piston Crank End Guide

Multi-stage compressors w/ HXs
49
ProcessDesign
Design
3/1/17
Economic optimization of # of stages
TAC = total annual cost

TAC = f(3 yr payback, energy cost)
50
ProcessDesign
Design
3/1/17
Gas turbines
Gas turbines consist of a compressor combustor
turbine/expander
Ideal gas turbine cycle is represented by the Brayton cycle
Gas exhaust is never at air conditions that you started at
Use heat to propel an engine (exhaust design)
Use heat to drive a steam turbine (combined cycle design
which is commonly used now)
Why dont we/Towler get in depth for designing gas
turbines?
Trends in GT tech fuel flexible, more efficient. Better
materials.
51
3/1/17
Brayton cycle
wikipedia
52
ProcessDesign
Design
3/1/17
GE 250MW 60Hz 7F7 + GE 9X
Turbofan engine
53
ProcessDesign
Design
3/1/17
Combined cycle
https://www.mhps.com/en/products/detail/cc
pp_mechanism.html
http://insights.globalspec.com/article/2895/combined-
cycle-power-plants-is-their-reign-assured
54
ProcessDesign
Design
3/1/17
Modeling combined cycle in Aspen
63MW for steam
turbine for same
amount of gas
RGibbs chemical-equilibrium reactor for combustor

Peng-Robinson physical properties for compressor and turbine energies
Assume 80% polytropic efficiencies
W. Luyben
In press Energy and Fuels (2013)
55
ProcessDesign
Design
3/1/17
Pressure drops
What you could do Process design applications
Pressure Across all unit ops A P across all unit ops

drops Process pressure requirements Process pressure requirements obvious
Heights Rough heights (z direction)
Piping Piping b/w units assume 10psi loss
How it changes over time Some changes later on
Valves All types in the right place. Over design pumping to some
reasonable degree
Include valves to shut off and some
expected control points (later on)
Turbine You can go nuts here Pick out std gas turbine products
design (Watts, EFF, gas flow, pressures)
Pumps Pump curves, optimized config Realistic eff, pump size (assume
and sizes centrifugal for most cases)
Materials, wear rates/replacement Think about sizes at start
compres Pick one of the three types These are expensive versus pumps.
sors Why?
56
3/1/17
General Pressure Drop Guidance
Losses between Unit Ops:
Pressure drops between unit operation steps: assume a
constant (10 psig Towler) pipe friction loss.
Gases will be much less of a drop, but more expensive to push
gases around.
Think about height changes early (think about actual equipment
sizes and orientation vertical vs. horizontal)
Across Unit Ops:

Across heat exchange steps a constant pressure drop or can
tailor by equipment type
Reactors Ergun equation for plug flow packed beds (most
reactors have some catalyst)
Columns See Prof Bequettes lecture (each tray as a drop)
Hunt around web for equipment spec sheets or other
57
ProcessDesign
Design
3/1/17
Overview Design Guidance
1. Figure out all pressure drops (you can do this)
2. Fix entrance and exit streams at 1atm
3. Include shutoff and control valves as needed (basic, crude control and
operability thinking unfort)
4. Figure out pumping requirements. Where are you putting all the
pumps?
5. Backup pumps for critical areas
6. Overdesign (reasonable). 35% more capacity (Dalakos crude
observation from vacuum pumping basically control valves should
start off as 75% open + 10% safety factor)
7. Looking ahead for costing, pumps, turbines and compressors are
functions of Watts. Think about material (corrosion - later). Think about
replication of equipment.
58
3/1/17

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Equipment fluid movement, work

on fluids, fluids that produce work

Towler ch. 5(?)

Negative work input (example: pumps,

Moody diagram plots out friction factor as a

Velocity head: Turns, bends, valves

Velocity head (N/m2)

2007 G.P. Towler / UOP. For educational use in conjunction with

We need to overcome frictional pressure losses in the piping and

2007 G.P. Towler / UOP. For educational use in conjunction with

Pressure at CV = 40 10 12 10 10 = -2 psi !?!

p across CV = +22 psi?!?

2007 G.P. Towler / UOP. For educational use in conjunction with

2007 G.P. Towler / UOP. For educational use in conjunction with

2007 G.P. Towler / UOP. For educational use in conjunction with

Suggested pipe velocities (ft/s):

Rule of thumb for liquids:

2007 G.P. Towler / UOP. For educational use in conjunction with

P=5 P=5 P=5

P=5 P=5 P=5

What is the pressure delivered by the pump? Assume

2007 G.P. Towler / UOP. For educational use in conjunction with

Chemical Engineering Design

Valves work by restricting or blocking the fluid flow path

Source: Valve Manufacturers Association, www.vma.org Shell = body + bonnet

Source: Valve Manufacturers Association, www.vma.org

Flow path is straight through

Not for complete shut-off, so a blind

Source: Valve Manufacturers Association, www.vma.org

2007 G.P. Towler / UOP. For educational use in conjunction with

Seat Limited to < 450F due to

2007 G.P. Towler / UOP. For educational use in conjunction with

Masoneilan 41005 Control Valve Source: Valve Manufacturers

Used for throttling (controlling) flow

2007 G.P. Towler / UOP. For educational use in conjunction with

Source: Valve Manufacturers Association, www.vma.org

2007 G.P. Towler / UOP. For educational use in conjunction with

Source: Valve Manufacturers Association, www.vma.org

2007 G.P. Towler / UOP. For educational use in conjunction with

Source: Tyco Flow Control

2007 G.P. Towler / UOP. For educational use in conjunction with

Most common type of pump for liquid service

Rotating shaft spins impeller, fluid enters at center and is discharged

2007 G.P. Towler / UOP. For educational use in conjunction with

Open Partially Open Enclose

Most casings can handle a range of impeller size as well as different

2007 G.P. Towler / UOP. For educational use in conjunction with

0 400 800 1200 1600 2000 2400 = (P2-P1)(bar) (10.2)/S.G.

100 ft. 100 ft. 100 ft.

32.5 psi 43 psi 52

Gasoline, S.G. = 0.75 Water, S.G. = 1.0 Brine, S.G. = 1.2

ote: head is same even though density is different

More flow, but never more head

2007 G.P. Towler / UOP. For educational use in conjunction with

2007 G.P. Towler / UOP. For educational use in conjunction with

Actual power produced (W = positive)

Shaftwork required = power delivered / efficiency

2007 G.P. Towler / UOP. For educational use in conjunction with

P=5 P=5 P=5