Fluids project:

Chilled water system

Mahmood AlAraibi - 201700841
Summary

The purpose of this project is to design a piping system for a chilled water supply
for A/C units, provided data and proposed schematic by GPIC.
Several steps were taken to achieve our goals:
 Material choice and pipe sizing, valves.
 Pressure drop calculations.
 Venturi design as a flow measurement device(Ratio of 0.8).
 Pump choice and calculations.
The material of choice: Stainless steel Schedule 80S with pipe dia of 3” for coil 2
and 3.5” for the rest of the system.
The suitable pump type is W+30/80 at 2900 RPM 50Hz, impeller diameter 150mm,
efficiency of 72%, 7.5kW motor.
 Introduction

Piping systems are an integral part in many industrial applications, the aim of
this project is to design a centralized chilled water plant for GPIC by analyzing
the system and deciding on pipe size, material used and other important aspects.
Design Schematic
 Data obtained

• Pipe
   lengths:- Tank to pump: 4 m, Pump to coils: 20 m, Return line: 35 m.
• Number of bends: Tank to pump: 3x90° bends, Pump to coils: 6x90° bends , Return line:
9x90° bends.
• Tanks height: 6m.
Conversion factor: gpm to m3/s = (X)(3.78*)/60 , wg to pa = X*248.84

 Coil 1  Coil 2  Coil 3

• Flow Rate: 0.01197 • Flow Rate: 0.00693 • Flow Rate: 0.00945

• Pressure drop: 14930 pa • Pressure drop: 11944 pa • Pressure drop: 12442 pa
• Pipeline length: 25 m • Pipeline length: 10 m • Pipeline length: 15 m
• No. 45° bends: 3 • No. 45° bends: 4 • No. 45° bends: 4
• No. 90° bends: 6 • No. 90° bends: 10 • No. 90° bends: 7
 Material of choice

Material Roughness(m) Cost

Cast iron 0.00026 Low
Copper 0.0000015 High
Stainless steel 0.000002 Med
Pressure drop calculations

 To determine suitable pipe size.

 To find the head losses.
To choose the suitable pump for this layout.
 Coil 1
HLmino Hlminor
Nominal Friction HLmajo Hlmajor r (m) (m) Total Total
(in) OD (in) OD (m) WT(in) WT (m) ID (m) Area ID (m^2) Velocity (m/s) Re Factor r (m) (pa) 6*90 3*45 Hlminor(m) Hlminor(pa)
0.0334 0.0033 169.87 166644 78.686 17.485
1 1.315 01 0.133 782 0.0300228 0.00070793 16.90837545 506623.527 0.014 19271 3.605 19091 8202 96.17201111 943447.429
0.0482 0.0036 24.381 239184 16.190 3.5978
1.5 1.9 6 0.145 83 0.044577 0.00156067 7.669774479 341213.111 0.0145 66494 .1331 48823 86273 19.7883745 194123.9538
0.0603 0.0039 7.8737 77241. 6.3121 1.4026
2 2.375 25 0.154 116 0.0564134 0.00249951 4.78894356 269621.346 0.0152 52438 51141 04703 89934 7.714794637 75682.13539
0.0054 1.1433 11216. 1.3205 0.2934
3 3.5 0.0889 0.216 864 0.0834136 0.00546467 2.190435851 182347.445 0.0156 77961 5378 52995 56221 1.614009216 15833.43041
0.0080 0.6825 6695.9 0.8356 0.1857
3.5 4 0.1016 0.318 772 0.0935228 0.0068695 1.74248588 162636.885 0.0165 68094 93006 67075 03795 1.02137087 10019.64824
0.0060 0.3101 3042.9 0.4650 0.1033
4 4.5 0.1143 0.237 198 0.1082802 0.00920848 1.299888706 140471.267 0.0156 90788 71628 57977 46217 0.568404194 5576.04514
0.0065 0.1039 1019.6 0.1939 0.0430
5 5.563 0.1413 0.258 532 0.134747 0.01426028 0.839394384 112880.115 0.0156 3902 41786 21908 93757 0.237015665 2325.123676
0.1682 0.0071 0.0424 416.59 0.0947 0.0210
6 6.625 75 0.28 12 0.161163 0.02039955 0.586777676 94378.0945 0.0156 66594 72839 63681 58596 0.115822277 1136.216537
0.2190 0.0081 0.0112 109.95 0.0323 0.0071
8 8.625 75 0.322 788 0.2108962 0.03493232 0.342662643 72122.0052 0.0158 08896 92744 16795 8151 0.039498304 387.4783661
0.2730 0.0092 0.0049 48.882 0.0132 0.0029
10 10.75 5 0.365 71 0.263779 0.0546475 0.219040203 57662.8801 0.0215 82954 78303 05122 34472 0.016139594 158.3294153
 Coil 2
HLmino Hlminor
Nominal Friction HLmajo Hlmajor r (m) (m) Total Total
(in) OD (in) OD (m) WT(in) WT (m) ID (m) Area ID (m^2) Velocity (m/s) Re Factor r (m) (pa) 10*90 4*45 Hlminor(m) Hlminor(pa)
0.0334 0.0033 0.0152 24.808 243371 43.956 7.8145
1 1.315 01 0.133 782 0.0300228 0.00070793 9.78905947 293308.358 5 56141 .9874 73638 30912 51.77126729 507876.1321
0.0482 0.0036 3.5168 34500. 9.0445 1.6079
1.5 1.9 6 0.145 83 0.044577 0.00156067 4.440395751 197544.433 0.0156 84573 63766 47901 19627 10.65246753 104500.7065
0.0603 0.0039 1.0834 10628. 3.5261 0.6268
2 2.375 25 0.154 116 0.0564134 0.00249951 2.772546272 156096.569 0.0156 30172 44999 52673 71586 4.15302426 40741.16799
0.0076 0.1991 1953.2 0.8182 0.1454
3 3.5 0.0889 0.3 2 0.08128 0.00518868 1.335598625 108340.775 0.0178 08239 51824 67747 69822 0.963737568 9454.265546
0.0080 0.1014 995.68 0.4668 0.0829
3.5 4 0.1016 0.318 772 0.0935228 0.0068695 1.008807615 94158.1964 0.0183 96552 11761 31561 92278 0.549823839 5393.771857
0.0060 0.0418 410.59 0.2597 0.0461
4 4.5 0.1143 0.237 198 0.1082802 0.00920848 0.752567146 81325.4701 0.0157 54495 2599 96931 86121 0.305983052 3001.693737
0.0065 0.0178 175.26 0.1083 0.0192
5 5.563 0.1413 0.258 532 0.134747 0.01426028 0.48596517 65351.6454 0.02 65788 33797 3126 58891 0.12759015 1251.659375
0.1682 0.0071 0.0076 74.830 0.0529 0.0094
6 6.625 75 0.28 12 0.161163 0.02039955 0.339713392 54639.9494 0.0209 2794 09243 3816 11228 0.062349388 611.6474985
0.2190 0.0081 0.0020 20.527 0.0180 0.0032
8 8.625 75 0.322 788 0.2108962 0.03493232 0.198383635 41754.8451 0.022 92506 47911 53242 09465 0.021262707 208.5871537
0.2730 0.0092 0.0007 7.0110 0.0073 0.0013
10 10.75 5 0.365 71 0.263779 0.0546475 0.126812749 33383.7727 0.023 14685 56378 76823 11435 0.008688258 85.23180898
 Coil 3
HLmino Hlminor Total
Area ID Velocity Friction HLmajo r (m) (m) Hlminor
Nominal (in) OD (in) OD (m) WT(in) WT (m) ID (m) (m^2) (m/s) Re Factor r (m) Hlmajor(pa) 7*90 4*45 (m) Total Hlminor(pa)
0.0334 0.0033 0.0300 0.0007 13.348 399965 65.794 57.216 14.531 71.747
1 1.315 01 0.133 782 228 0793 71746 .943 0.0145 28121 645441.8987 41305 15252 56558 703843.6183
0.0482 0.0036 0.0445 0.0015 6.0550 269378 9.5579 11.772 2.9899 14.762
1.5 1.9 6 0.145 83 77 6067 85115 .772 0.0152 66657 93763.6529 86194 33191 79513 144823.0202
0.0603 0.0039 0.0564 0.0024 3.7807 212858 2.9444 4.5898 1.1656 5.7554
2 2.375 25 0.154 116 134 9951 44916 .957 0.0152 78058 28885.32975 26827 70305 97132 56461.42687
0.0054 0.0834 0.0054 1.7292 143958 0.4275 0.9602 0.2438 1.2041
3 3.5 0.0889 0.216 864 136 6467 91461 .509 0.0156 79016 4194.550145 35904 69436 0534 11812.27338
0.0080 0.0935 0.0068 1.3756 128397 0.2660 0.6076 0.1543 0.7619
3.5 4 0.1016 0.318 772 228 695 46747 .541 0.0172 82954 2610.273778 52652 24483 77135 7474.995693
0.0060 0.1082 0.0092 1.0262 110898 0.1159 0.3381 0.0858 0.4240
4 4.5 0.1143 0.237 198 802 0848 27926 .368 0.0156 99325 1137.953379 65426 83283 48709 4159.917836
0.0065 0.1347 0.0142 0.6626 89115. 0.0391 0.1410 0.0358 0.1768
5 5.563 0.1413 0.258 532 47 6028 79777 8802 0.0157 18324 383.7507575 09698 11987 21684 1734.620723
0.1682 0.0071 0.1611 0.0203 0.4632 74509. 0.0158 0.0161 0.0689 0.0175 0.0864
6 6.625 75 0.28 12 63 9955 45534 0219 5 3536 158.2878824 07109 00218 07327 847.6558775
0.2190 0.0081 0.2108 0.0349 0.2705 56938. 0.0056 0.0234 0.0059 0.0294
8 8.625 75 0.322 788 962 3232 23139 4252 0.0212 24296 55.17434751 99054 68014 67068 289.0719365
0.2730 0.0092 0.2637 0.0546 0.1729 45523. 0.0019 0.0096 0.0024 0.0120
10 10.75 5 0.365 71 79 475 26476 3264 0.022 06767 18.70538757 02063 38619 40682 118.1190866
 Tank to pump
Area ID
Nominal (in) OD (in) OD (m) WT(in) WT (m) ID (m) (m^2) Velocity (m/s) Re Friction Factor HLmajor (m) Hlmajor(pa) HLminor (m) 3*90 Total Hlminor(pa)
0.0080 0.0935 0.0068 385192
3.5 4 0.1016 0.318 772 228 695 4.126940241 .622 0.014 0.519789957 5099.139474 0.781267695 7664.23609

Pump to coil
Area
Nominal OD(m^ Area ID Velocit Friction HLminor (m)
(in) OD (in) OD (m) WT(in) WT (m) ID (m) 2) (m^2) y (m/s) Re Factor HLmajor (m) Hlmajor(pa) 6*90 Total Hlminor(pa)
0.0080 0.0935 0.0081 0.0068 4.1269 385192 2.59894978
3.5 4 0.1016 0.318 772 228 0732 695 40241 .622 0.014 3 25495.69737 1.56253539 15328.47218

Return to tank
Area ID Velocit
Nominal (in) OD (in) OD (m) WT(in) WT (m) ID (m) (m^2) y (m/s) Re Friction Factor HLmajor (m) Hlmajor(pa) HLminor (m) 9*90 Total Hlminor(pa)
0.0080 0.0935 0.0068 4.1269 385192
3.5 4 0.1016 0.318 772 228 695 40241 .622 0.014 4.54816212 44617.4704 2.343803086 22992.70827
 
Taking coil 2 as an example to show steps for calculations:
Calculations are made on a 3-inch nominal pipe, note that wall thickness and inner
diameter values obtained for Stainless steel schedule 80S.

Area of a circular pipe is found by the formula

Obtaining velocity from flow rate by Q = A . U where Q(flow rate) = 0.00693 gives u = 1.33
m/s.

Reynolds number to determine the flow type is given by: where density and viscosity at
20 Celsius is taken as 1000 kg/m3 and 0.001002 Pa.s respectively.
Re = = 108340
For Re > 4000 = turbulent flow.

Relative roughness e = = 0.000002/0.08128 = 2.46 *

Friction factor obtained by moody chart: f = 0.016.

Friction factor obtained by Colebrook equation: f = 0.0178
 - Major head loss:
= 0.1991 m

- Minor head loss:

For 90 degrees bend : k = 0.9 n = 10

=
For 45 degrees bend : k = 0.4 n = 4
=
For check valve k = 0.2, gate valve k = 0.15
Total head loss: +

Total pressure drop:

= 1000(9.81) × 1.162 = 11407 pa
Venturi design

0.02835
 

0.0935 m
0.075 m
0.0068 m^2 0.0044 m^2
4.12 m/s 6.45 m/s
58860 pa 46580 pa
 Calculations sample for venturi
Ratio Velocity 2 Pressure 1 Pressure 2
(D2/D1) D2 (m) D1 (m) Area D2 (m^2) Area D1 (m^2) (m/s) Velocity 1 (m/s (pa) (pa) dp (pa)
0.1 0.009352 0.09352 6.86908E-05 0.006869085 412.7187367 4.127187367 58860.28 -85101000.71 85159861
0.2 0.018704 0.09352 0.000274763 0.006869085 103.1796842 4.127187367 58860.28 -5255646.496 5314506.78
0.3 0.028056 0.09352 0.000618218 0.006869085 45.85763741 4.127187367 58860.28 -984084.3368 1042944.62
0.4 0.037408 0.09352 0.001099054 0.006869085 25.79492105 4.127187367 58860.28 -265311.8581 324172.138
0.5 0.04676 0.09352 0.001717271 0.006869085 16.50874947 4.127187367 58860.28 -68892.28673 127752.567
0.6 0.056112 0.09352 0.002472871 0.006869085 11.46440935 4.127187367 58860.28 1660.776869 57199.5031
0.7 0.065464 0.09352 0.003365852 0.006869085 8.422831362 4.127187367 58860.28 31905.07371 26955.2063
0.8 0.074816 0.09352 0.004396214 0.006869085 6.448730261 4.127187367 58860.28 46584.05679 12276.2232
0.9 0.084168 0.09352 0.005563959 0.006869085 5.095293046 4.127187367 58860.28 54396.11217 4464.16783

 Calculations sample is for the chosen 0.8 Ratio.

-Diameter 2:-

-Velocity 2 :-
From law of conservation of mass,
 Alternative flow measurement devices
Differential pressure flowmeter:
A disk or orifice is placed in the pipe, opening of the orifice is set lower
than inside diameter.

ADVANTAGES DISADVANTAGES
Applicable for liquid, gas and steam. Not accurate
Can be used for extreme pressure High maintenance cost.
and temperature.
Comes in range of sizes. Very long inlet and outlet.
 Turbine flowmeter:
As fluid flows through it, a turbine blade is rotated about an axis along the
centerline of the turbine housing, the angular velocity is directly proportional to
fluid velocity.

ADVANTAGES DISADVANTAGES
Easy to install. Frequent/difficult calibration
checks.
Highly accurate and precise. Affected by viscosity.
Economical to purchase. Can only measure clean sample.
Pump selection
  Converting unit for flow rate(Q):

Given that:

- Calculated Total head loss = 18.3m

Pump performance graph can be used

 
From this graph we get pump type W+30/80 W = 7.5 kW
RPM = 2900, 50 Hz, impeller diameter = 150mm and efficiency = 0.72

Calculation of power consumption can be done using the formula:

As seen the calculated power consumption is similar with graph value.

 
The NPSHA (net positive suction head) Available was found to compare with required NPSH.
The NPSH required was taken from the chart.
NPSH calculation:-

NPSHA > NPSHR

 Pump types and attributes
Pumps are mainly classified into two types:-

Centrifugal pumps: Most common kinetic energy pump, pushes fluid outward via
impeller. Centrifugal pumps comes in many designs such as:-
• Self-Priming centrifugal pump: Uses a mixture of air and water to reach primed
state in order to avoid damage.
• Long coupled centrifugal pump: Includes a coupling between the pump shaft
and the motor shaft, gained popularity due to availability of motors.
Positive displacement pumps: Works by repeatedly enclosing a fixed volume
and mechanically moving it, usually used for specific applications like
pumping high viscosity liquid or high pressures low flowrate application.

Property  Centrifugal  Positive Displacement 

Effective viscosity range Efficiency decreases with increasing Efficiency increases with increasing
viscosity (max. 200 Cp)  viscosity 

Pressure tolerance   Flow varies with changing pressure  Flow insensitive to changing pressure

Efficiency decreases at both higher and Efficiency increases with increasing

lower pressures pressure 

Priming Required Not required 

Flow (at constant pressure) Constant Pulsing

Shearing (separation of emulsions, slurries, High speed motor damages shear-sensitive Low internal velocity.  Ideal for pumping
biologican fluids, food stuffs) mediums shear sensitive fluids

(“Centrifugal vs positive displacement – michael smiths engineers", 2019)

Pump curves
35

30

25
Pressure Drop

20

15

10

0
0 50 100 150 200 250 300

Flowrate
 0.9

0.8

0.7

0.6

0.5
Efficiency

0.4

0.3

0.2

0.1W = 7.5*10^3

0
20 40 60 80 100 120 140 160 180 200 220

Flowrate
Pump arrangement
  In series -

Where flow rate is constant along the system while the pressure head is
the sum of all pumps pressure head.
 In parallel -

Where the pressure head is constant along the system, and the flow rate is
added up.

-Point 3 is pressure head at both pumps running.

-Parallel setup to achieve high flow rate, series arrangement applied where one
pump can’t handle pressure head.
Selection of check valves
Check valves are designed to allow the flow in one direction to prevent backflow
from occurring.

Comes in many designs most common:

Swing check valve, tee-pattern lift valve and tilting disc check valve.
Selection of valve design is dependent on flow type, velocity, and even location in
system.

Swing check valve

Tilting disc check valves are recommended for our
system return lines where velocity is higher than 4
m/s ( uniform flow ), for the coils a swing check or
guided disc valves can be applied.
 References
Akki. (2013). Check valve types. Retrieved from Piping Guide:
http://www.pipingguide.net/2013/10/check-valves-types-construction.html
Emerson. (n.d.). Turbine Flow Meter Working Principle. Retrieved from emerson:
https://www.emerson.com/en-us/automation/measurement-instrumentation/flow-
measurement/about-liquid-turbine-flow-meters
Engineer edge. (n.d.). Water - Density viscosity. Retrieved from
https://www.engineersedge.com/physics/water__density_viscosity_specific_weight_13146
.htm
Engineering Toolbox. (2004). Pumps in parallel or series. Retrieved from Engineering
toolbox: https://www.engineeringtoolbox.com/pumps-parallel-serial-d_636.html
Engineering toolbox. (n.d.). ASME/ANSI B36.10/19 - Carbon, Alloy and Stainless Steel Pipes
- Dimensions. Retrieved from Engineering toolbox:
https://www.engineeringtoolbox.com/steel-pipes-dimensions-d_43.html
Kinnas. (2000). The venturi meter. Retrieved from Kinnas:
http://cavity.caee.utexas.edu/kinnas/COURSES/ce319/ebook/venturi/venturi.html
McMillan. (n.d.). Commonly asked questions for turbine flowmeters. Retrieved from McMillan flow
producs: https://www.mcmflow.com/turbine-flow-meters/
Michael Smith Engineers. (n.d.). Useful information on positive displacement. Retrieved from
michael smith engineers: https://www.michael-smith-engineers.co.uk/resources/useful-
info/positive-displacement-pumps
Moodle. (n.d.). Pump manual. Retrieved from Moodle:
https://moodle.polytechnic.bh/moodle/pluginfile.php/65632/mod_resource/content/1/Pump
%20Catalogue.pdf
Shorts, M. (2007, May 1). Understanding check valves. Retrieved from Waterworld:
https://www.waterworld.com/technologies/valves/article/16197251/understanding-check-valves-
sizing-for-the-application-not-the-line-size
Simetric. (n.d.). Density of water. Retrieved from Simetric:
https://www.simetric.co.uk/si_water.htm
Test and measurement world. (n.d.). Advantages of Differential Pressure Flowmeter |
disadvantages of Differential Pressure Flowmeter. Retrieved from Test and measurement world:
https://www.test-and-measurement-world.com/Terminology/Advantages-and-Disadvantages-of-
Differential-Pressure-Flowmeter.html