Process Design Principles - II

CHAPTER 5

PROCESS DESIGN OF PIPING, FLUID MOVING

DEVICES AND FLOW METERS
 Introduction

A fluid is a substance which when in static eqbm cant

sustain tangential or shear forces
All fluids are compressible but for simplicity Gases
are considered compressible and liquids not.
Ambient air is considered incompressible
In a pump/fan or compressor mechanical work is
converted to fluid energy.
A turbine is a machine for transforming fluid energy
into mechanical work at the rotating shaft.
The word pump is normally used for a machine
handling liquid
 Process Design of Piping

Design of Piping systems incorporates all major disciplines of

engineering
Chemical
Mechanical
Instrumentation
Control
Electrical

Designing of a pipe is a balance between diameter of pipe and

pressure drop in pipe.
We have to come up with an optimum pipe size balancing pipe costs

and pumping costs

 Process Design of Piping

The term Piping means not only pipe but includes

components like fittings, flanges, valves, bolts,

gaskets, bellows etc.
 Process Design of Piping

For larger size of pipe , P is less implies that the

pumping cost will be less.

But the larger size of pipe increases the fixed cost of

pipe.

Ideally one should find the pipe size which gives the

sum of capital cost plus operating cost a minimum or

one should find the optimum pipe size.
Optimum Pipe Size
 Recommended Fluid Velocities in Pipe
Velocity
Fluid
(ft/min) (m/s)
Acetylene, steel pipe 4000 20
Air, 0-30 psi, steel pipe 4000 20
Ammonia, liquid, steel pipe 360 1.8
Ammonia, gas, steel pipe 6000 30
Benzene, steel pipe 360 1.8
Bromine, liquid, glass pipe 240 1.2
Bromine, gas, glass pipe 2000 10
Calcium Chloride, steel pipe 240 1.2

Carbon Tetrachloride, steel pipe 360 1.8

Chlorine, liquid, steel pipe 300 1.5

Chlorine, gas, steel pipe 2000 - 5000 10 - 25
Chloroform, liquid, steel or copper pipe 360 1.8
 Recommended Fluid Velocities in Pipe
Also refer to values given in RB 1

Chloroform, gas, steel or copper pipe 2000 10

Ethylene, gas, steel pipe 6000 30
Ethylene Dibromide, glass pipe 240 1.2
Hydrogen, steel pipe 4000 20
Hydrochloric Acid, liquid, rubber lined pipe 300 1.5

Hydrochloric Acid, gas, rubber lined pipe 4000 20

Methyl Chloride, liquid, steel pipe 300 1.5
Methyl Chloride, gas, steel pipe 4000 20
Natural gas, , steel pipe 6000 30
Oil lubricating, steel pipe 300 1.5
Oxygen, stainless steel 1800 - 4000 9 - 20
Propylene Glycol, steel pipe 300 1.5
Perchlorethylene, steel pipe 360 1.8
Steam, 0-30 psi, saturated, steel pipe 4000 - 6000 20 - 30
Sulfuric acid 240 1.2
Pressure Drop in Pipe
Pressure Drop in Pipe
Standard Pipes
Standard Pipes
 Pressure Drop in Fittings and Valves

In addition to pipes, piping systems contains fittings

and valves.
These fittings and valves offer the additional
frictional loss or additional pressure drop.
This is denoted by
Equivalent straight pipe length Le
No. of velocity heads

Lost in the pipe of same size and material

Losses in valves and fittings
 Losses in valves and fittings

Fitting Type Le/D

Gate valve, full open 8
Ball valve, full bore 3
Ball valve, reduced bore 25
Globe valve, full open 320
90 screwed elbow 30
90 long radius bend 13
45 screwed elbow 16
45 long radius bend 10
Welded Tee, thru-run 10
Welded Tee, thru-branch 60
 Losses in valves and fittings

Another way of calculating pressure drop through

the fittings and valves is the use of factor K.
No of velocity heads (K) lost in pipe for fittings or
valves is defined by equation
{F /(v2/2)} = {(p/)/(v2/2)} = K
Where F = additional frictional loss, J/kg
p=additional pressure drop, N/m2
v= average fluid velocity, m/s
 Process Design of Fluid Moving Devices

PUMP
Pump is used to increase mechanical energy of the
flowing fluid
There are two types
Centrifugal Pump and
Positive Displacement
The following terminologies are used
Capacity Flow rate in (Volume/time)
Total dynamic head difference between total discharge head
hd and total suction head hs
H = hd - hs
 Positive Displacement Pumps

In this class of pumps, a definite volume of liquid is

trapped in a chamber, which is alternately filled from
the inlet and emptied at a higher pressure through
the discharge.
There are two subclasses of positive displacement
pumps
reciprocating pumps
rotary pumps
 Positive Displacement Pumps

Reciprocating pumps
In Reciprocating pumps, the chamber is a stationary
cylinder that contains a piston or plunger.
Types
Piston Pump
Plunger Pump
Diaphragm Pump
 Piston
Pumps
In this pump liquid is drawn through an
inlet check valve into the cylinder by the
withdrawal of a piston and then is forced
out through a discharge check valve on
the return stroke.
Most of the piston pumps are double acting
with liquid admitted alternately on each
side of the piston so that one part of the
cylinder is being filled while the other is
being emptied.
The maximum discharge pressure for
commercial piston pumps is about 50 atm
 Plunger pump
It consists of a heavy walled cylinder of small diameter
contains a close fitting reciprocating plunger
At the limit of its stroke the plunger fills nearly all the
space in the cylinder.
These pumps can discharge very high pressure upto 1500
atm
 Diaphragm
Pump
Fluid is transferred by the pressure of a
diaphragm that flexs to form a cavity that
is filled by liquid
Flexible diaphragm of rubber, thermo-plastic,
metal is
used. This eliminates the need for packing or
seals.
Can handle highly viscous liquids.
Can handle toxic or corrosive liquids
They can develop pressures in excess of 100 atm.
Rotary Pump
In Rotary pumps, the chamber moves from inlet to
discharge and back to the inlet.
A wide variety of rotary pumps are available like
Gear pumps
Lobe pumps
Screw pumps
Vane pumps
 Gear Pump

Drive Gear
As the gears rotate they
separate on the intake Delivery
side of
the pump, creating a void
and
suction which is filled by
fluid.
The fluid is carried by the
gears to the discharge Inlet
side of
the pump
The tight clearances,
along
 Screw Pump
Delivery
spindle.

cylindrical cavity Inlet

Single Screw Rotor

A single screw rotates in a cylindrical cavity,
thereby moving the material along the
screw'sspindle.
 Centrifugal Pumps

This pumps generate high rotational velocities,

then
convert the resulting kinetic energy of the liquid
to
pressure energy.
parts: It contains impeller and casing.

Use:
Centrifugal pumps are generally used where high
flow rates and moderate head increases are
Centrifugal Pumps
Centrifugal Pumps
 Impellers

Impeller
Vanes

Eye of the
Impeller Thickness
Water of the impeller
Diameter of
Entrance
the Impeller

Thicker the Impeller- More Water

Larger the DIAMETER - More Pressure
Increase the Speed - More Water and
Pressure
Process Design of Pump
Process Design of Pump
Process Design of Pump
 Net Positive Suction Head (NPSH)

In a hydraulic circuit, net positive suction head (NPSH)

may refer to one of two quantities in the analysis of

cavitation:
The Available NPSH (NPSHA): a measure of how close the
fluid at a given point is to boiling, and so to cavitation.
The Required NPSH (NPSHR): the head value at a specific
point (e.g. the inlet of a pump) required to keep the fluid from
cavitating.
 Net Positive Suction Head (NPSH)

(NPSH)R depends on properties of liquid, the total head,

pump speed, capacity & impeller design.

Practical curves of (NPSH)R vs capacity and speed of

pump are supplied by pump manufacturer.

Following figures can be used as a guideline to find the

value of (NPSH)R, for centrifugal pump handling water at

Temperatures below 100 C and above 100 C
respectively.
Net Positive Suction Head (NPSH)
Net Positive Suction Head (NPSH)
NPSH
NPSH for Liquids saturated with dissolved Gases

In many cases the liquid to be pumped is saturated with

gases
NPSHA calculations differ for such pumps
Pumping of cooling water (saturated with air), pumping
of condensate from a knockout drum of a compressor,
pumping of solution from an absorber, etc can be cited as
examples of such situations where the liquids are
saturated with gases.
NPSH for Liquids saturated with dissolved Gases
NPSH for Liquids saturated with dissolved Gases
NPSH for Liquids saturated with dissolved Gases
NPSH for Liquids saturated with dissolved Gases
Power required for Pumping
Power required in Fan, Blower and in Adiabatic
Compressor
 Power required by Fan,

Efficiency of a fan ranges from 40% to 70%,

depending on the specific speed.
Power input to a fan is given by equation
Power required in Blower and in Adiabatic
Compressor
Power required in Blower and in Adiabatic
Compressor
Power required in Blower and in Adiabatic
Compressor