M 389 Content

PUMPS
PROCESS PUMPS, VALVES, & PIPE SPREADSHEET ANALYSIS

© Copy Write, John Andrew P.E. 10 May 2013
This 3 PDH course includes spread sheets that can be used to calculate the: motor power required
to drive a centrifugal pump supplying liquids though: piping, fittings, and valves.
Pump Performance
Excel's, "Goal Seek" adjusts one input numerical value to cause a calculated formula cell to equal
the desired value that you type in the Goal Seek dialog box, To value: [ ]
When using Goal Seek unprotect the spread sheet by selecting: Drop down menu:
Tools > Protection > Unprotect Sheet > OK
Pick the cell containing formula result > Data > What If > Goal Seek >
By changing the value in the cell containing a numerical value >
Next type in the box, To value: [ ]
When Excel's Goal Seek is not needed, restore protection with drop down menu:
Tools > Protection > Protect Sheet > OK
PROCESS FLOW DIAGRAMS

Above is the image at: www.absoluteastronomy.com/topics/Process_Flow...
The process flow diagram above depicts a single chemical engineering unit process
known as an amine treating plant.
A process flow diagram (PFD) is a diagram commonly used in chemical

engineering.
Chemical engineering is the branch of engineering that deals with the application of
physical science and life sciences with mathematics, to the process of converting raw
materials or chemicals into more useful or valuable
Pageforms
1 and process engineering.
PUMPS
A process flow diagram (PFD) is a diagram commonly used in chemical
engineering.
Chemical engineering is the branch of engineering that deals with the application of
physical science and life sciences with mathematics, to the process of converting raw
materials or chemicals into more useful or valuable forms and process engineering.
Process engineering
Process engineering focuses on the design, operation and maintenance of chemical and
other process manufacturing activities. Process engineering is often a synonym for
chemical engineering but process engineers are found in a vast range of industries, such
as the petrochemical, mineral processing,...
to indicate the general flow of plant processes and equipment. The PFD displays the
relationship between major equipment of a plant facility and does not show minor details
such as piping details and designations. Another commonly-used term for a PFD is a flow
sheet.
PROCESS PUMP AND PIPING EXAMPLE
The centrifugal pump above must be flooded before starting the driver motor. An
Pump Specific Speed
eccentric reducer at the pump suction flange prevents cavitation. Cavitation
includes air bubbles and severe turbulence that can damage the pump. The gate valve
between the pump and tank must not be used for throttling or controlling flow rate but
must be fully open for operation or fully closed for maintenance.
Page 2
PUMPS
Pump Selection
Input
Fluid flow rate, q = 100 gpm
Pump impellor rotational speed, n = 1750 rpm
Allowable pressure head loss, H = 250 ft
Pump efficiency, EffP = 70%
Drive efficiency - Gear or Belt, EffD = 90%
Motor efficiency see chart right, EffM = 89%
Output
Pump specific speed, Ns = n * q^0.5 / H^0.75
= 278 dimensionless
Centrifugal pump type from diagram above = Radial Vane
Minimum pump drive motor power, PM = q * H / (3960 * EffP * EffD * EffM)
= 11.26 hp
Standard motor power, PS = 15 hp
Pump efficiencies typically range from about 50% to 80%. See "Systems).
Power that is not converted into kinetic energy is lost as heat.
The volute of a centrifugal pump is the casing that receives

the fluid being pumped by the impeller, slowing down the
fluid's rate of flow. A
volute is a curved funnel that increases in area as it
approaches the discharge port. The
volute converts kinetic energy into pressure by reducing
speed while increasing pressure, helping to balance the
hydraulic pressure on the shaft of the pump.
The volute also plays a role in pump efficiency.
At specific speeds below 2000, its losses range from 1 to
2.5% but losses can approach 10% at speeds over 5000.
Typically, volute design begins with the throat, as its cross
sectional area will determine the flow velocity out of the
volute.
Flow through the throat and other portions of the casing
follows the law of constant angular momentum so the
designer will try to avoid abrupt changes its nearly circular
Page 3
Typically, volute design begins with the throat, as its cross
sectional area will determine the flow velocity out of thePUMPS
volute.
Flow through the throat and other portions of the casing
follows the law of constant angular momentum so the
designer will try to avoid abrupt changes its nearly circular
geometry while gradually increasing its volume.
Another critical area of the volute is the clearance between
the outer circumference of the impeller and that of the volute
tongue or cutwater. As this
distance becomes larger, an increasing volume of pumpage
escapes entry into the volute throat and is re-circulated into
the volute case. The
smallest distance possible, that does not give rise to
pressure pulsations, will produce the best efficiency.
As a rule of thumb, 5 to 10% of the impeller radius tends
to be a safe value.
Pump efficiency decreases when smaller impellers are
installed in a pump because of the increased amount of fluid
that slips through the space between the tips of the impeller
blades and the pump casing.
AFFINITY LAWS
The affinity laws are used in hydraulics and HVAC to
express the relationship between variables involved in pump or fan performance (such as
head, volumetric flow rate, shaft speed, and power). They apply to pumps, fans, and
hydraulic turbines. In these rotary implements, the affinity laws apply both to centrifugal and
axial flows. http://en.wikipedia.org/wiki/Affinity_laws
Q is the
volumetric flow rate (e.g. CFM, GPM or L/s),
D is the impeller diameter (e.g. in or mm),
N is the shaft rotational speed (e.g. rpm),
H is the pressure or head developed by the fan/pump (e.g. ft or m), and
P is the shaft power (e.g. W).
Law 1. With impeller diameter (D) held constant:
Law 1a. Flow is proportional to shaft speed:
Q1/Q2/ = N1/N2
H1/H2 = (N1/N2)^2
P1/P2 = (N1/N2)^3
Law 2. With impeller speed (N) held constant:
Law 1a. Flow is proportional to shaft speed:
Q1/Q2/ = D1/D2
H1/H2 = (D1/D2)^2
P1/P2 = (D1/D2)^3
Note:
END OF the above affinity laws are approximate and not exact for pumps because of the
WORKSHEET
losses described above.
Page 4
PUMPS
``
Page 5
PUMPS
Page 6
PUMPS
DETERMINING ELECTRIC MOTOR LOAD AND EFFICIENCY

US Department of energy
http://www1.eere.energy.gov/industry/bestpractices/pdfs/10097517.pdf
Page 7
PIPING

Process Piping Pressure Head Loss
http://commons.wikimedia.org/wiki/File:Piping_system_on_a_chemical_tanker.jpg
Conversion Factors
Input Units Output
10 gallons 1.337
10 gallons/min (gpm) 80.21
10 gallons/min (gpm) 0.0223
10 inches (in) 0.8333
10 pounds mass (lbs) 0.3106
10 US Barrels 420.0
10 feet water 4.33
10 inches mercury (in ) 4.90
Reynolds Number, Re Input

Fluid flow rate,
q = 269.0 gpm
Pipe internal diameter,d = 6.000 in
Length of straight pipe,
L = 100 ft
Fluid viscosity,
µ = 0.00002730 ft^2/sec
Fluid density,
ρ = 62.47 lbs/ft^3
Gravitational constant,g = 32.2 ft/sec^2
Output
Pipe internal diameter, D = d/12
= 0.5000 ft
Pipe internal area, A= 3.1416*D^2/4
= 0.1964 ft^2
Fluid flow volume, Q = q / 448.831
= 0.599 ft^3/sec
Fluid flow velocity, V = Q / A
= 3.05 ft/sec
Page 8
PIPING
Fluid mass density, ρM = ρ / 32.2

= 1.9400 slugs/ft^3
Reynolds number, Re = D * V * ρM / µ
= 108,455 dimensionless
= 1.085E+05
Moody Diagram
Fluid flow when: Re =
1.629 x 10^5 is turbulent as indicated
on the Moody diagram left.
Diagram
left is the image at:
www.engineeringtoolbox.com/moody-
diagram-d_61...
Density and Viscosity

of Water
Temp (F) (Slugs/ft^3)
32 1.94
40 1.94
50 1.94
60 1.938
70 1.936
www.engineeringtoolbox.com/moody-diagram-d_61...
Normal fluid flow velocity, V = 10 ft/sec Pipe Material Roughness

Pressure drop, h = 4 ft per 100 ft of pipe inches feet
Laminar Flow Re < 2,100 Drawn brass 0.00006 0.000005
Turbulent Flow Re > 4,000 Copper 0.00006 0.000005
PVC 0.00006 0.000005
Commercial Steel 0.0018 0.000150
Wrought iron 0.0018 0.000150
Asphalted cast iron 0.0048 0.000400
Galvanized iron 0.006 0.000500
Cast Iron 0.0102 0.000850
Concrete .012 to .120 0.001 to .01
Turbulent Fluid in Pipe, Friction

Input
Reynolds number, Re = 1.00 x 10^7
= 10,000,000
Pipe Material = Commercial Steel
Pipe internal diameter, d = 4.000 in
Roughness, e = 0.00180 in
Pipe straight length, L = 100 ft
Output
Page 9
PIPING
e / d= 0.00045
Moody fluid in pipe friction factor, f = (1.14 + (2* Log10(d/e)))^-2
= 0.0163
PROBLEM - Turbulent Region Fluid Static Head Loss

Moody turbulent fluid in pipe friction factor, f is a function of roughness only.
Input
Fluid flow rate, q = 2000.0 gpm
Length of straight pipe, L = 100 ft
Fluid viscosity, µ = 0.00002730 ft^2/sec
Fluid density, ρ = 62.47 lbs/ft^3
Gravitational constant, g = 32.2 ft/sec^2
Output
= 1.1667 ft
Relative roughness, e / d= 0.00013
= 1.0690 ft^2
= 4.456 ft^3/sec
= 4.17 ft/sec
= 1.9400 slugs/ft^3
Reynolds number, Re = D * V * ρ / µ
= 345,580
= 3.456E+05
is a function of roughness only. = 0.0126
Darcy Weisbach pressure head loss, hL = f * (L/D) * (V^2 / (2 * g)
= 0.291 ft
Straight Pipe flow friction pressure drop, ΔP = ρM * g * hL
= 18.1 lbs/ft^2
Straight Pipe flow friction pressure drop, Δp = ΔP / 144
= 0.126 psi
MOODY DIAGRAM for conditions above:

From the Moody diagram, the point for
Re = _____________and Roughness ε/D = _____________, is
in the _______________ region and the friction factor, f, is
approximately: f = ___________ and ___________ by the Darcy
Weisbach formula.
PROBLEM - Transition Region Fluid Static Head Loss: Re is between 2,100 and 4000
Input
Page 10
PIPING

Output
= 0.3333 ft
e / d= 0.0054
= 0.0873 ft^2
= 0.013 ft^3/sec
= 0.153 ft/sec
= 1.9400 slugs/ft^3
Reynolds number, Re = D * V * ρM / µ
= 3,629 Re<4,000 OK
= 3.629E+03
NOTE: Moody fluid in pipe friction factor, f above applies to turbulent flow only.
Laminar/turbulent transition region friction f equation Re is between 2,100 and 4000

Equation is: f = ((-2 * Log((e/D) / 3.7)) + (2.51 / (Re * f^0.5)))^-2
Divide both sides of the friction equation by f.
Now 1 = Right side of the equation / f
Pick Cell containing formula result, C200 > Data > What If > Goal Seek > >
by changing the value in the cell containing the guessed value of f in
C197.
Guess transition friction factor, f = 0.0310

Transition friction formula, f = ((-2 * Log((e/D) / 3.7)) + (2.51 / (Re * f^0.5)))^-2
Divide both sides of friction equation by f, 1 = [((-2 * Log((e/D) / 3.7)) + (2.51 / (Re * f^0.5)))^-2] / f
Data > What If > Goal Seek > C200 = 1: 1 = 1.000
by changing the value in cell C197
Transition friction factor f from above

Input from above
Transition friction factor, f = 0.0310
Output
= 0.0034 ft
= 0.212 lbs/ft^2
= 0.001 psi
Smooth Pipe - turbulent flow friction f

Input
Roughness, e = 0.0005 ft
Page 11
PIPING

Output
= 0.2500 ft
e / d= 0.0020
= 0.0491 ft^2
= 0.600 ft^3/sec
= 12.223 ft/sec
= 1.9400 slugs/ft^3
Reynolds number, Re = D * V * ρ M
/ µ
= 217,150
= 2.171E+05
Smooth Pipe turbulent flow friction factor, f = .316 / (Re^0.25)
= 0.0146
= 13.58 ft
= 848.57 lbs/ft^2
= 5.893 psi
Pipe Fittings and Valves

Loss Factor K is the number of velocity heads (V^2 / 2g) lost by flow though a fitting or valve.
Input
Standard Fitting Factor K Fitting Quantity N
Elbow, 90 deg long radiu 0.45 4
Elbow, 90 deg short radi 0.75 0
Elbow, 45 deg long radiu 0.20 0
Elbow, 45 deg short radi 0.35 0
Bend, 180 deg close retu 1.50 0
Tee, branch blocked 1.00 0
Tee, used as elbow 1.00 0
Coupling 0.04 0
Union 0.04 0
Gate Valve, full open 0.17 0
Gate Valve, 3/4 open 0.90 0
Glob Valve, full open 6.00 0
Glob Valve, 1/2 open 9.50 5
Y or Blow-off, open 3.00 0
Butterfly valve angle, 5 d 0.24 0
Butterfly valve angle, 10 0.52 0
Check valve, swing 2.00 0
Check valve, disk 10.0 0
Page 12
PIPING
Check valve, ball 70.0 0

Number of fittings, ΣN = 19
TOTAL VALVE & FITTING PRESSURE HEAD LOSS

Input
Output
= 0.3333 ft
= 0.0873 ft^2
= 0.668 ft^3/sec
Average fluid flow velocity, V = Q / A
= 7.659 ft/sec
Input
Sum of velocity head factors above, ΣNK = 128.800
Output
Sum of fitting head loses, hF = Σ(N*K) * (V^2 / (2*g))
= 117.33 ft
Fitting flow friction pressure drop, ΔP = ρ * hL
= 7321.41 lbs/ft^2
Fitting flow friction pressure drop, Δp = ΔP / 144
= 50.843 psi
TOTAL PIPE, VALVE, & FITTING PRESSURE HEAD LOSS

Input loss from above. Input
Sum of straight pipe head loses from above, h = 13.58 ft
Sum of fitting head loses, hF = 7.25 ft
Output
TOTAL Pipe and Fittings pressure drop, H = h + hF
= 20.83 ft
Laminar Fluid Flow in Pipe Head Loss f

Input
Fluid flow rate,q = 5.0 gpm
Length of straight pipe,L = 100 ft
Fluid viscosity,µ = 0.00002730 ft^2/sec
Fluid density,ρ = 62.47 lbs/ft^3
Output
= 0.5000 ft
= 0.1964 ft^2
= 0.011 ft^3/sec
= 0.06 ft/sec
= 1.9400 slugs/ft^3
Page 13
PIPING
= 2,016 Re<2,100 Laminar OK
Revise flow rate, pipe diameter until Re < 2,100 for laminar flow
Laminar Fluid Flow in Pipe Head Loss, f = 64 / Re
= 0.03175
is a function of Reynolds number only. = 0.000317 ft
Negligible
Taylor Engineering - Publications

http://www.taylor-engineering.com/publications/design_guides.shtml
Schedule 40 pipe size VS friction pressure loss graph.
Process Industry Rules of Thumb - (repeated from above)

Normal fluid flow velocity, V = 10 ft/sec
Pressure drop, h = 4 ft per 100 ft of pipe
Laminar Flow Re < 2,100
Turbulent Flow Re > 4,000
PIPE EXPANSION LOOP
CONVERT MERTIC TO US UNITS

Input: meters Sch 40
Pipe length meters, L = 10 m Nominal Diameter
Pipe diameter millimeters, D = 50 mm 4
Page 14
PIPING
Temperature Centigrade, T = 100 deg C 6

Output: ft 8
Pipe length feet, L = 32.81 ft 10
Pipe diameter inches, D = 1.969 in 12
Temperature Fahrenheit, T = 212 deg F 14
16
Pipe Section Properties (inch units) 18
See "PIPE & FITTINGS" tab below. Input 20
PIPE: SCH 40, Steel 24
Nominal Pipe Diameter, Dn = 8 in
Pipe (ID 1 to 12 in) or (OD 14 in and larger) dia, D = 8.000 in
Pipe wall thickness, w = 0.320 in
Pipe (ID 1 to 12 in) Output
Pipe internal diameter, D1 = 8.000 in D<=12, OK
Pipe external diameter, D2 = 8.640 in
Pipe cross section area, Ap = π*(DX^2 - DI^2)/4
= 8.364 sq in
Pipe section modulus, Ix = π*(D2^4 - D1^4)/ 64
= 72.481 in^4
Pipe (ID 14 in and larger)
Pipe internal diameter, D1 = 7.360 in
Pipe external diameter, D2 = 8.000 in D=<12, Not OK
Pipe cross section area, Ap = π*(DX^2 - DI^2)/4
= 7.721 sq in
Pipe section modulus, Ix = π*(D2^4 - D1^4)/ 64
= 57.023 in^4
Pipe Anchor Force due to Thermal Expansion

Input
Pipe material = Steel 0.22% C

Pipe material thermal coefficient of expansion, α = 6.5 10-6 in/in-deg F
Pipe length, A = 30 ft ABS (Acrylonitrile butadi
Pipe length, B = 30 ft ABS -glass fib
Pipe length, C = 4 ft
Pipe length, H = 7.39 ft
Pipe low temperature, TL = 70 deg F
Pipe high temperature, TH = 200 deg F Steel Stainless F
Pipe material modulus of elasticity, E = 29,000,000 lb/sq in
Pipe outside diameter, D2 = 8.75 in
Pipe section area, A = 9.867 sq in
Pipe section modulus, I = 71.960 in^4
Pipe material allowable bending stress, Sa= 62,000 lbs/sq in
Output
Total pipe length between rigid supports, Lf = A + B + C
= 64 ft
Total pipe length (inches), Li = 768 in
Temperature change, ΔT = TH - TL
= 130 deg F
Un-restricted total pipe thermal expansion, X = α*10-6*Li*ΔT
= 0.649 in
Pipe A, B,& C anchored compressive stress, Sc = E*α*ΔT
= 24,505 lb/sq in
Page 15
PIPING
Pipe compressive force without expansion loop, F = A*Sc

= 204,965 lbs
Pipe material input above = Steel 0.22%C
Pipe loop member E deflection, Y = X / 2
= 0.324 in
Pipe compressive force with expansion loop, Fe = 12*E*I*(Y) / (12*H)^3
= 11644 lbs
Pipe D moment, M = Fe*E*12 / 2
= 516,407 in-lbs
Pipe D bending stress, Sb = M*(D2/2) / Ix
= 31,002 lbs/sq in
Pipe safety factor = Applied Stress / Allowable Stress
= 2.00 <<< Use "GOAL SEEK" to adjust H ft to
obtain the desired safety factor.
Pipe Bending Stress With Expansion Loop
Enter "OK" pipe section values from above:
PIPE TRAVEL WITH RUN & SET
CALCULATE PIPE TRAVEL INPUT

Pipe nominal diameter (12 or less) (14 or more) D = 10 in
SET = 36.000 in
Page 16
PIPING
CALCULATIONS
45 deg long radius Elbow, RL = 1.5*D
= 15 in
45 deg short radius Elbow, RS = D
= 10 in
RUN = SET
= 36.000 in
TRAVEL = (RUN^2 + SET^2)^(1/2)
= 50.912 in
Long radius Pipe spool travel length, LL = TRAVEL - 2*(RL*SIN(22.5 / 57.3))
= 39.432 in
Short radius Pipe spool travel length, LS = TRAVEL - 2*(RS*SIN(22.5 / 57.3))
= 43.259 in
PIPE TRAVEL WITH ROLLING OFFSET
CALCULATE TRAVEL INPUT

RUN = 60.000 in
ROLL = 48.000 in
SET = 24.000 in
CALCULATIONS
AC = BD = (ROLL^2 + SET^2)^(1/2)
= 53.666 in
ELBOW ANGLE, DAB = 57.30*ATAN(BD / RUN)
= 41.8 deg
TRAVEL = (RUN^2 + BD^2)^(1/2)
= 80.498 in
ELBOW ANGLE, DBE = 57.30*ATAN(SET / ROLL)
26.57 deg
TRAVEL CALCULATION METHOD
Page 17
PIPING
1 AB must equal BD for a 45 degree triangle.

2 Given any two dimensions from RUN, ROLL, and SET
3 Type a trial value for the third unknown dimension.
4 Use "Goal Seek" to make angle DAB = 45 degress and find the third dimension.
Pick the cell with a formula: C544
Data > What-If Analysis > Goal Seek
Pick the "To value" box > Type 45
Pick the "By changing cell" box > Pick cell C539 or other cell with unknown dimension.
OK > OK
Page 18
PIPING
Spread Sheet Method: Excel Worksheet

1. Type in values for the Input Data.
2. Excel will make the Calculations.
Excel's GOAL SEEK

Excel's, "Goal Seek" adjusts one Input value to cause a Calculated formula cell to
equal a given value.
When using Excel's Goal Seek, unprotect the spread sheet by selecting: Drop down
menu: Home > Format > Unprotect Sheet > OK
When Excel's Goal Seek is not needed, restore protection with:

Drop down menu: Home > Format > Protect Sheet > OK
To scroll, roll the mouse wheel.

To zoom in, depress the Ctrl key and roll the mouse wheel away from you.
To open another, "Work Sheet Lesson" select a tab at the bottom of this spreadsheet.
To unlock the cells of this spreadsheet: Home > Format > Unprotect Sheet.
To lock the cells of this spreadsheet: Home > Format > Protect Sheet.
Units To open a new spreadsheet topic click on the tabs below.
cu ft (ft^3)
gallons/hr (gph)
cu ft per sec (cfs)
feet (ft)
slugs
gallons
pounds per sq in (psi)
pounds per sq in (psi)
Page 19
PIPING
Dynamic
Viscosity
lb-sec/ft^2
0.00003732
0.00003228
0.00002730
0.00002334
0.00002037
Page 20
PIPING
EXAMPLE - Turbulent Region Fluid Static Head Loss

Moody turbulent fluid in pipe friction factor, f is a function of roughness only.
Input
Output
= 0.5000 ft
Relative roughness, e / d= 0.00030
= 0.1964 ft^2
= 0.609 ft^3/sec
= 3.10 ft/sec
= 1.9400 slugs/ft^3
= 110,147
= 1.101E+05
= 0.445 ft
Pipe flow friction pressure drop, ΔP = ρM * g * hL
= 27.8 lbs/ft^2
Pipe flow friction pressure drop, Δp = ΔP / 144
= 0.193 psi
MOODY DIAGRAM for conditions above:

From the Moody diagram, the point for Re = 1.10 x 10^5 and Roughness
ε/D = 0.00030, is in the turbulent region and the friction factor, f, is
approximately: f = 0.015 and 0.0149 by the Darcy Weisbach formula.
EXAMPLE - Transition Region Fluid Static Head Loss: Re is between 2,100 and 4
Input
Page 21
PIPING

Output
= 0.3333 ft
e / d= 0.0054
= 0.0873 ft^2
= 0.013 ft^3/sec
= 0.153 ft/sec
= 1.9400 slugs/ft^3
= 3,629 Re<4,000 OK
= 3.629E+03
Laminar/turbulent transition region friction f equation Re is between 2,100 and 4

Equation is: f = ((-2 * Log((e/D) / 3.7)) + (2.51 / (Re * f^0.5)))^-2
Divide both sides of the friction equation by f.
Now 1 = Right side of the equation / f
Pick Cell containing formula result, C200 > Data > What If > Goal Seek > >
by changing the value in the cell containing the guessed value of f in
C197.
Guess transition friction factor, f = 0.0310

Transition friction formula, f = ((-2 * Log((e/D) / 3.7)) + (2.51 / (Re * f^0.5)))^
Divide both sides of friction equation by f, 1 = [((-2 * Log((e/D) / 3.7)) + (2.51 / (Re * f^0.5)))
Data > What If > Goal Seek > C200 = 1: 1 = 1.000
by changing the value in cell C197
Chosen friction factor f from above

Input from above
Transition friction factor, f = 0.0310
Output
= 0.0034 ft
Pipe flow friction pressure drop, ΔP = ρM * g * hL
= 0.212 lbs/ft^2
Pipe flow friction pressure drop, Δp = ΔP / 144
= 0.001 psi
Page 22
PIPING
N*K
1.800
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
22.500
0.000
0.000
47.500
0.000
0.000
0.000
0.000
0.000
590.000
0.000
0.000
Page 23
PIPING
0.000
661.800 =Σ(N*K)
Page 24
PIPING
0
Wall thick in
0.237
Page 25
PIPING
0.280
0.322
0.365
0.406
0.437
0.500
0.562
0.593
0.687
Material Thermal 10
-6
Expansion Coefficient in/in-

(α) deg F
Aluminum Alloy 6061 13.1
trile butadiene styrene) 73.8
S -glass fiber-reinforced 30.4
Stainless Steel 304 9.6
Stainless Ferritic (410) 5.5
Steel 0.22% C 6.5
Page 26
PIPING
Page 27
PIPING
TRAVEL EXAMPLE ONLY INPUT

RUN = 60.000 in
ROLL = 48.000 in
SET = 35.991 in
CALCULATIONS
AC = BD = (ROLL^2 + SET^2)^(1/2)
= 59.995 in
ELBOW ANGLE, DAB = 57.30*ATAN(BD / RUN)
= 45.0 deg
TRAVEL = (RUN^2 + BD^2)^(1/2)
84.849 in
ELBOW ANGLE, DBE = 57.30*ATAN(SET / ROLL)
36.87 deg
Page 28
PIPING
nd 4000
Page 29
PIPING
and 4000
0.5)))^-2
^0.5)))^-2] / f
Page 30
SYSTEMS

Pump and Piping Systems
Net Positive Suction Head NPSH

Pipe and fittings heads Hfd and Hfs are calculated under "PIPING" tab below.
System Head = total discharge head - total suction head

System Head, H = Hd - Hs
Total discharge head, Hd = Hsd + Hpd + Hfd
Total suction head, Hs = Hss + Hps = Hfs
LIQUID Input
Liquid name is: Water
Fluid spedific gravity, SG = 1.00
Liquid teperature, t = 68 deg F
DISCHARGE
Discharge static head , Hsd = 40 ft
Discharge surface pressure, Hpd = 3.00 psig
Discharge friction head (pipe and fittings), Hfd = 26.00 ft
SUCTION
Absolute pressure in liquid suction tank, Ps = 14.7 psia
Suction static head, Hss = -10 ft
Suction surface pressure, Hps = 2.00 psig
Suction friction head (pipe and fittings), Hfs = 3 ft
Output
Total discharge head, Hd = Hsd + Hpd + Hfd Suction static head, Hs
= 69.00 ft
Total suction head, Hs = Hss + Hps + Hfs
Page 31
SYSTEMS
= -5.00 ft
Pumping System Head, H = Hd + Hs
= 64.00 ft
Available NPSH is "the difference between the total suction head and
the vapor pressure of the liquid, in feet of liquid, at the suction flange."
NPSHA is a function of your system and must be calculated, whereas NPSHR

function of the pump and must be provided by the pump manufacturer.
NPSHA MUST be greater than NPSHR for the pump system to operate without cavitating.
Output
Gage suction pressure, Psg = Ps - 14.7
= 0.00 psig
Total suction head, in feet of liquid, absolute, Hsa = Pd*2.31 / SG
= 34.0 ft
Vapor pressure of liquid at suction nozzle, Hypa = 0.000002*T^3 - 0.0002*T^2 + 0.0112*T - 0.1436
= 0.322 psi
= 0.74 ft
Available net position suction head (NPSHA), Hsv = Hsa - Hypa
= 33.21 ft
pdf TOTAL DIFFERENTIAL HEAD (THD)

http://www.sealing.com/fileadmin/docs/Pump_Formulas.pdf 2.00E-06
Pipe Internal Roughness

Pipe Material Roughness
inches feet
Drawn brass 0.00006 0.000005
Copper 0.00006 0.000005
PVC 0.00006 0.000005
Commercial Steel 0.0018 0.000150
Wrought iron 0.0018 0.000150
Asphalted cast iron 0.0048 0.000400
Galvanized iron 0.006 0.000500
Cast Iron 0.0102 0.000850
Concrete .012 to .120 0.001 to .01
Page 32
SYSTEMS
PROBLEM - TURBULENT Region Fluid Static Head Loss

Use this calculation Input
Suction + Discharge length of straight pipe, L = 143.0 ft
Motor efficiency, EffM = 90%
Output
= 0.1667 ft
e / d= 0.0009
= 0.0218 ft^2
= 0.290 ft^3/sec
= 13.28 ft/sec
= 1.9400 slugs/ft^3
= 157,239
= 1.572E+05
= 0.0191
Darcy Weisbach friction pressure head loss, Hfd or Hfs = f * (L/D) * (V^2 / (2 * g)
= 44.9 ft
Minimum motor power, PM = q * H / (3960 * EffP * EffD * EffM)
= 2.60 hp
GPM
System Head Loss VS Flow Rate 0
50 10
45 40
40 f(x) = 0.0026539421x^2 + 0.000250998x + 0.0175149701 70
R² = 0.9999980599
HEAD LOSS h (ft)
35 100
30 130
25
20
15
10
5
0
0 20 40 60 80 100 120 140
Page 33
20
SYSTEMS
HEAD
15
10
5
0
0 20 40 60 80 100 120 140
FLOW q (gpm)
The above
was used toDarcy Weisbach
obtain values toliquid in the
create pipeSystem
frictionHead
pressure
Loss head loss,Rate
VS Flow Hf = f * (L/D) * (V^2 / (2 * g)
graph.
The above Darcy Weisbach pressure head loss curve has been plotted on the pump performance graph.
The amount of fluid power that a system consumes is a

product of head and flow, according to this equation:
Fluid power = QH (s.g.)
3,960
where
H = head (ft)
Q = flow rate (gallons per minute [gpm])
sg = specific gravity of the fluid
3,960 is a units conversion to state fluid power in terms of
horsepower.
Input
Fluid flow rate, Q = 130 gpm
Head, H = 44.9 ft
Specific gravity of the fluid, sg = 1
Calculate
Fuid power, P = Q*H*sg / 3960
= 1.5 hp
END OF WORKSHEET
Page 34
SYSTEMS
2.31 ft = 1 psi
atic head, Hss Discharge static head , Hsd
Page 35
SYSTEMS
EXAMPLE - TURBULENT Region Fluid Static Head Loss

Example only Input
Suction + Discharge length of straight pipe, L = 143.0 ft
Motor efficiency, EffM = 90%
Output
= 0.1667 ft
e / d= 0.0009
= 0.0218 ft^2
= 0.290 ft^3/sec
= 13.28 ft/sec
= 1.9400 slugs/ft^3
= 157,239
= 1.572E+05
= 0.0191
= 44.9 ft
Minimum motor power, PM = q * H / (3960 * EffP * EffD * EffM)
= 2.60 hp
Head Loss (ft) System Head Loss VS Flow Rate GPM Head Loss (ft)
0 0 0
0.3 50 10 0.3
4.3 45 40 4.3
13.0 40 f(x) = 0.0026539421x^2 + 0.000250998x + 0.0175149701 70 13.0
R² = 0.9999980599
HEAD LOSS h (ft)
26.6 35 100 26.6

44.9 30 130 44.9
25
20
15
10
5
0
0 20 40 60 80 100 120 140
Page 36
SYSTEMS
HEAD
15
10
5
0
0 20 40 60 80 100 120 140
FLOW q (gpm)
The abovethe
to create Darcy Weisbach
System pressure
Head Loss headRate
VS Flow loss, h L = f * (L/D) * (V^2 / (2 * g) was used to obtain values
graph.
The above Darcy Weisbach pressure head loss curve has been plotted on the pump performance graph.
Page 37
SYSTEMS
Page 38
http://www.cranepumps.com/pumpselector.php
Free Vendor Piping System Software
CRANE PUMPS AND SYSTEMS
PUMP CALCULATOR
http://www.cranepumps.com/ > PRODUCTS > MENTOR PUMP

SELECTION > MENTOR ONLINE > BARNS > Start Pump
Selection > Enter; GPM, Head (feet of water), Pump Type, Speed,
etc.
http://www.pump-flo.com/select/centrifugal/headcalc.aspx
Mentor, is an electronic guide for selecting and evaluating Crane's
centrifugal pump product lines. Mentor is available for CP&S
centrifugal pump product lines including:
Barnes, Deming and Weinman and International products.
Pump Calculator may be found under menu option:
Products > Mentor Pump Selection.
SELECT FLOW SYSTEM

ENTER FLOW PARAMETERS
ADD PIPE FITTINGS
CALCULATED VALUES
RATED DESIGN POINT
Click on “SEARCH”.
Click on the pump row to select a pump. Click on a column header to sort the list.
SELECTED PUMP: 6SE300*4L

SELECTED PUMP: 6SE300*4L PERFORMANCE CURVES
The red arrow above is the operating point 60 GPM (Gallons per Minute)
and 40.8 feet head ( Effective distance water is lifted).
Note: Pump efficiency in this example is less than 30% and maximum
efficiency is 80%. See efficiency curves above.
END OF WORKSHEET
Pressure Drop Calculator
The Flowmaster Calculator is a free download at:

http://www.flowmaster.com/pd-cal-form.html
Conversion Factors
Input Output
Length (ft) = 100 30.48 (m)
Pipe Internal Diameter (in) = 12 0.3048037064 (m)
Roughness (in) = 0.001 0.00002540 (mm)
Inlet Flow (gpm) = 60 0.003785 (m^3/s)
END OF WORKSHEET
Pipe Sizing Based on First Costs and Future Energy Costs
Taylor Engineering - Publications

http://www.taylor-engineering.com/publications/design_guides.shtml
A free spreadsheet has been developed as part of the CoolTools™

Chilled Water Plant Design Guide, funded by California utility customers
through Energy Design Resources (www.energydesignresources. com).
The spreadsheet provides these basic
functions:
Pipe sizing based on a balance between first costs and future energy
costs, with optional velocity limits for erosion and noise generation; and
Pump head calculations including all fittings, valves, and devices.
The spreadsheet is fast and easy to use—calculations for most systems
can be done in a few hours.
WATER CONVERSION TABLE

http://dnrc.mt.gov/wrd/water_rts/wr_general_info/wrforms/615.pdf
Darcy-Weisbach Formula vs. Hazen-Williams

http://www.vikinggroupinc.com/techarticles/frictionloss.pdf
END OF WORKSHEET
STANDARD PIPE DIMENSIONS
Nom. Outside
Pipe Size Diameter Light WT STD XS XXS SCH 20 SCH 30
½ 0.84 - 0.109 0.147 0.294 - -
¾ 1.05 - 0.113 0.154 0.308 - -
1 1.315 - 0.133 0.179 0.358 - -
1¼ 1.66 - 0.14 0.191 0.382 - -
1½ 1.9 - 0.145 0.2 0.4 - -
2 2.375 - 0.154 0.218 0.438 - -
2½ 2.875 - 0.203 0.276 0.552 - -
3 3.5 - 0.216 0.3 0.6 - -
3½ 4 - 0.226 0.318 0.636 - -
4 4.5 0.188 0.237 0.337 0.674 - -
5 5.562 - 0.258 0.375 0.75 - -
6 6.625 0.219 0.28 0.432 0.864 - -
8 8.625 0.219 0.322 0.5 0.875 0.25 0.277
10 10.75 0.219 0.365 0.5 1 0.25 0.307
12 12.75 0.25 0.375 0.5 1 0.25 0.33
14 14 0.25 0.375 0.5 - 0.312 STD
16 16 0.25 0.375 0.5 - 0.312 STD
18 18 0.25 0.375 0.5 - 0.312 0.438
20 20 0.25 0.375 0.5 - STD XS
22 22 - 0.375 0.5 - STD XS
24 24 0.25 0.375 0.5 - STD 0.562
26 26 - 0.375 0.5 - XS -
28 28 - 0.375 0.5 - XS 0.625
30 30 - 0.375 0.5 - XS 0.625
32 32 - 0.375 0.5 - XS 0.625
34 34 - 0.375 0.5 - XS 0.625
36 36 - 0.375 0.5 - XS 0.625
38 38 - 0.375 0.5 - - -
40 40 - 0.375 0.5 - - -
42 42 - 0.375 0.5 - - -
44 44 - 0.375 0.5 - - -
46 46 - 0.375 0.5 - - -
48 48 - 0.375 0.5 - - -
PIPE INTERNAL DIAMETER Input

Nominal pipe size = 6 in
Pipe schedule = xs
Pipe outside diameter, D = 6.625 in
Pipe wall thickness, t = 0.432 in
Calculate
Pipe outside diameter, d = D - 2*t
5.761 in
STANDARD FITTINGS
Hackney Ladish link to dimensions of pipe fittings above:
http://pccenergygroup.com/PDFs/PCC-materials/Conversion%20Booklet.pdf
END OF WORKSHEET
SCH 40 SCH 60 SCH 80 SCH 100 SCH 120 SCH 140 SCH 160
STD - XS - - - 0.188
STD - XS - - - 0.219
STD - XS - - - 0.25
STD - XS - - - 0.25
STD - XS - - - 0.281
STD - XS - - - 0.344
STD - XS - - - 0.375
STD - XS - - - 0.438
STD - XS - - - -
STD - XS - 0.438 - 0.531
STD - XS - 0.5 - 0.625
STD - XS - 0.562 - 0.719
STD 0.406 XS 0.594 0.719 0.812 0.906
STD XS 0.594 0.719 0.844 1 1.125
0.406 0.562 0.688 0.844 1 1.125 1.312
0.438 0.594 0.75 0.938 1.094 1.25 1.406
XS 0.656 0.844 1.031 1.219 1.438 1.594
0.562 0.75 0.938 1.156 1.375 1.562 1.781
0.594 0.812 1.031 1.281 1.5 1.75 1.969
- 0.875 1.125 1.375 1.625 1.875 2.125
0.688 0.969 1.219 1.531 1.812 2.062 2.344
- - - - - - -
- - - - - - -
- - - - - - -
0.688 - - - - - -
0.688 - - - - - -
0.75 - - - - - -
- - - - - - -
- - - - - - -
- - - - - - -
- - - - - - -
- - - - - - -
- - - - - - -
http://www.hackneyladish.com/DimensionData-pr5.aspx
tings above:
Conversion%20Booklet.pdf

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PUMPS

PROCESS PUMPS, VALVES, & PIPE SPREADSHEET ANALYSIS

PROCESS FLOW DIAGRAMS

A process flow diagram (PFD) is a diagram commonly used in chemical

PROCESS PUMP AND PIPING EXAMPLE

The volute of a centrifugal pump is the casing that receives

DETERMINING ELECTRIC MOTOR LOAD AND EFFICIENCY

PROCESS PUMPS, VALVES, & PIPE SPREADSHEET ANALYSIS

Process Piping Pressure Head Loss

Reynolds Number, Re Input

Fluid mass density, ρM = ρ / 32.2

Density and Viscosity

Normal fluid flow velocity, V = 10 ft/sec Pipe Material Roughness

Turbulent Fluid in Pipe, Friction

PROBLEM - Turbulent Region Fluid Static Head Loss

MOODY DIAGRAM for conditions above:

Fluid density, ρ = 62.47 lbs/ft^3

Laminar/turbulent transition region friction f equation Re is between 2,100 and 4000

Guess transition friction factor, f = 0.0310

Transition friction factor f from above

Smooth Pipe - turbulent flow friction f

Length of straight pipe, L = 100 ft

Pipe Fittings and Valves

Check valve, ball 70.0 0

TOTAL VALVE & FITTING PRESSURE HEAD LOSS

TOTAL PIPE, VALVE, & FITTING PRESSURE HEAD LOSS

Laminar Fluid Flow in Pipe Head Loss f

Taylor Engineering - Publications

Schedule 40 pipe size VS friction pressure loss graph.

Process Industry Rules of Thumb - (repeated from above)

PIPE EXPANSION LOOP

CONVERT MERTIC TO US UNITS

Temperature Centigrade, T = 100 deg C 6

Pipe Anchor Force due to Thermal Expansion

Pipe material = Steel 0.22% C

Pipe compressive force without expansion loop, F = A*Sc

Enter "OK" pipe section values from above:

PIPE TRAVEL WITH RUN & SET

CALCULATE PIPE TRAVEL INPUT

PIPE TRAVEL WITH ROLLING OFFSET

CALCULATE TRAVEL INPUT

1 AB must equal BD for a 45 degree triangle.

Spread Sheet Method: Excel Worksheet

Excel's GOAL SEEK

When Excel's Goal Seek is not needed, restore protection with:

To scroll, roll the mouse wheel.

EXAMPLE - Turbulent Region Fluid Static Head Loss

MOODY DIAGRAM for conditions above:

Fluid density, ρ = 62.47 lbs/ft^3

Laminar/turbulent transition region friction f equation Re is between 2,100 and 4

Guess transition friction factor, f = 0.0310

Chosen friction factor f from above

Expansion Coefficient in/in-

TRAVEL EXAMPLE ONLY INPUT

PROCESS PUMPS, VALVES, & PIPE SPREADSHEET ANALYSIS

Pump and Piping Systems

Net Positive Suction Head NPSH

System Head = total discharge head - total suction head

NPSHA is a function of your system and must be calculated, whereas NPSHR