CH-414 – Chemical Plant Design

• Final Year |Chemical Engineering Department|

Dr. Syed Ali Ammar Taqvi

PhD, (Chemical Engineering)
Assistant Professor, Department of Chemical Engineering
NED University of Engineering and Technology Karachi
Pumps & Piping Hydraulics
Lecture No. 7

CH-414|Chemical Plant Design| Dr. Syed A. Taqvi

Objectives
▪ Calculate & Select suitable line sizes for fluid
▪ Work up examples of circuits
▪ Hydraulics of a Tank-Pump-Tank Model
▪ Calculating Hydraulic Power, NPSHa,
▪ Determining Service of Pump (Flow/Pressure)
▪ Estimating
• Suction Speed, Efficiency, Power, Motor Rating

CH-414|Chemical Plant Design| Dr. Syed A. Taqvi

Recap…..
▪ Driving Forces of Nature
▪ Pressure, Temperature, Concentration, Voltage, Gravity, Magnetic
force.
▪ Material handling involved material transfer to the point of use
and run-down to storage.
▪ Material handling costs range from 30-50% of total cost in an
industry and sometime as high as 95%.
▪ Pumps transfer liquid by directly or by converting centrifugal
force/velocity to pressure.
▪ This pressure creates the potential to transfer from A to B.

CH-414|Chemical Plant Design| Dr. Syed A. Taqvi

Example 1….! Test your memory…..!
Calculating volume from flow rate: the heart pumps a lot of blood in
a lifetime

How many cubic meters of blood does the heart pump in a 75-year
lifetime, assuming the average flow rate is 5.00 L/min?

CH-414|Chemical Plant Design| Dr. Syed A. Taqvi

Example 1….! Test your memory…..!
Strategy
Time and flow rate Q are given, and so the volume V can be calculated from the definition
of flow rate.

Solution V
Solving for volume gives Q=
t
Substituting known values yields
V = 2.0 10 m 5 3
Discussion
This amount is about 200,000 tons of blood. For comparison, this value is equivalent to about 200 times the
volume of water contained in a 6-lane 50-m lap pool.

CH-414|Chemical Plant Design| Dr. Syed A. Taqvi

Energy of a Fluid in Motion

Pressure Energy

2 Kinetic Energy
u
U + Pv + gz +
Internal Energy
2
Pressure Energy

CH-414|Chemical Plant Design| Dr. Syed A. Taqvi

 Incompressible fluids
Example:
Water flows from a tap at a pressure of 250 kN/m2 above atmospheric. What
is the velocity of the jet if frictional effects are neglected?

Using suffix 1 to denote conditions in the pipe and suffix 2 to denote conditions in the jet
and neglecting the velocity of approach in the pipe:

u2 = 22.4 m/s
CH-414|Chemical Plant Design| Dr. Syed A. Taqvi
Frictional Groups
R
▪ Moody’s Friction Factor f '= 8 2
v
R
▪ Darcy or Fanning Friction Factor fD = 2 2
v
R
▪ Stanton/Pannel = 2
v

f ' = 4 f D = 8

CH-414|Chemical Plant Design| Dr. Syed A. Taqvi

Moody’s Diagram

CH-414|Chemical Plant Design| Dr. Syed A. Taqvi

Stanton’s Diagram

CH-414|Chemical Plant Design| Dr. Syed A. Taqvi

 Formulae
64
 Laminar f =
Re
1  2.51 e 
 Transient = −2  log  + 
f  Re f 3.7 DH 

[There are other equations for fully turbulent flow. We will use primarily
this equation for calculating friction loss. This is the Colebrook-White
equation.]

CH-414|Chemical Plant Design| Dr. Syed A. Taqvi

 Bernoulli’s Equation
2 2
P1 v P2 v
+ z1 + =1
+ z2 + − hL 2
g 2 g g 2g
 Liquids do not experience a significant change in density so:
P
− = z − hL
g
 For gas, with pressure drop density also changes so calculations require
some iteration for longer runs of pipe
PM
=
ZRT
CH-414|Chemical Plant Design| Dr. Syed A. Taqvi
 Pressure Drop/Head Loss
▪ The “magical” equation filled with so many concepts!

Pf v LEq. 
= hL = f 
g 2 g DH
▪ [Note again, if we have to calculate for gas, the pressure drop will result
in gas expansion or increasing velocity as gas flows]

CH-414|Chemical Plant Design| Dr. Syed A. Taqvi

 Example 2: Application of total energy balance for the flow
of an Ideal gas.
Nitrogen is flowing under turbulent conditions at a constant mass rate through a long, straight,
horizontal pipe. The pipe has a constant inside diameter of 2.067 in. At an upstream point (point l), the
temperature of the nitrogen is 70oF, the pressure is 15 psia, and the average linear velocity of the gas is
60 ft/s.
At a given downstream point (point 2), the temperature of the gas is 140°F and the pressure is
50 psia with average velocity of 18 ft/s. An external heater is located between points 1 and 2, and 10 Btu
is transferred from the heater to each pound of the flowing gas. Except at the heater, no heat is
transferred as such between the gas and the surroundings. Under these conditions, nitrogen may be
considered to be an ideal gas, and the mean heat capacity CP of the gas is 7.0 Btu/(lb moloF).

Estimate the total amount of energy (as foot-pounds force per pound of the flowing gas) supplied
by the compressor located between points 1 and 2.

CH-414|Chemical Plant Design| Dr. Syed A. Taqvi

Example 3 Application of total energy balance for the Row of
a nonideal gas (steam turbine).

Superheated steam enters a turbine under such conditions that the enthalpy of the
entering steam is 1340 Btu/lb. On the same basis, the enthalpy of the steam leaving the
turbine is 990 Btu/lb. If the turbine operates under adiabatic conditions and changes in
kinetic energy and elevation potential energy are negligible.

Estimate the maximum amount of energy obtainable from the turbine per pound of
entering steam.

CH-414|Chemical Plant Design| Dr. Syed A. Taqvi

 Pipe Fittings
▪ The pipes are fabricated from steel with or without small alloying ingredients, and they are welded or
drawn to give a seamless pipe. Tubes with diameters of 6 to 50 mm are frequently made from non-ferrous
metals such as copper, brass, or aluminium, and these are very widely used in heat exchangers.

▪ In addition, check valves are supplied for relieving the pressure in pipelines, and reducing valves are
available for controlling the pressure on the downstream side of the valve.
▪ Gate and globe valves are supplied in all sizes and may be controlled by motor units operated from an
automatic control system.
▪ Hand wheels are usually fitted for emergency use.

▪ In general, gate valves give coarse control, globe valves give finer and needle valves give the finest control
of the rate of flow.

▪ Diaphragm valves are also widely used for the handling of corrosive fluids since the diaphragm may be
made of corrosion resistant materials.

CH-414|Chemical Plant Design| Dr. Syed A. Taqvi

 Pipe Fittings
Table shows the friction losses in
various pipe fittings for turbulent
flow of fluid and are expressed in
terms of the equivalent length of
straight pipe with the same
resistance, and as the number of
velocity heads (u2/2g) lost.

CH-414|Chemical Plant Design| Dr. Syed A. Taqvi

 Practice Problem 1
 Calculate the pressure drop per 100 ft length in a 6” Sch-40 carbon steel
pipe in which 400USGPM of water is flowing at 35°C (density = 62.4
lb/ft³ viscosity = 0.8cP, Pipe ID = 6.065in, e= 0.0018in)
v= =
Q Q vD
Re =
A  D2 
4
Q vD
v = 0.4085  2 Re = 124.024 
D 

 V = 4.442 ft/s, Re = 260621

CH-414|Chemical Plant Design| Dr. Syed A. Taqvi

 Using Calculator (Casio 570MS/991ES etc.)
• Be in Computation mode Comp mode (Mode -1)
• For variable memory press [Alpha] Button

A= 2.51/Re = 2.51/260621 = 9.631x10-6

B= e/(3.7D) = 0.0018/(3.7 x 6.065) = 8.0212 x10-5
F= 0.015
Type the following in the calculator
(− 2  log(A  F +B ))
−2
→F
To store press [Shift+Sto] button. Press enter for each iteration

CH-414|Chemical Plant Design| Dr. Syed A. Taqvi

  2.51 e 
Practice #1 contd… 1
= −2  log  + 
f  Re f 3.7 DH 
▪ Take starting value of f = 0.015

▪ For 1 ft length, Pressure Drop

P
= f
2
v L
= 0.01719 
(4.442 )

2
100
= 1.043 ft
g 2g D 2  32.174  6.065 
 
 12 
62.4
P =  1.043 = 0.452 psi
144
CH-414|Chemical Plant Design| Dr. Syed A. Taqvi
 Power Requirements for Pumping Liquids
To transport a liquid from one vessel to another through a pipeline, energy has
to be supplied to;
1. Overcome the friction losses in the pipes;
2. Overcome the miscellaneous losses in the pipe fittings (e.g., bends),
valves, instruments etc.;
3. Overcome the losses in process equipment (e.g., heat exchangers, packed
beds);
4. Overcome any difference in elevation from end to end of the pipe;
5. Overcome any difference in pressure between the vessels at each end of
the pipeline.

CH-414|Chemical Plant Design| Dr. Syed A. Taqvi

Practice Problem 2:
A pipeline connecting two tanks contains four standard elbows, a
globe valve that is fully open, and a gate valve that is half open.
The line is commercial steel pipe, 25mm internal diameter, length
120 m. The properties of the fluid are viscosity 0.99 mNm-2s,
density 998 kg/m3. Calculate the total pressure drop due to
friction when the flow rate is 3500 kg/h.

CH-414|Chemical Plant Design| Dr. Syed A. Taqvi

Practice Problem 2:
Solution:

CH-414|Chemical Plant Design| Dr. Syed A. Taqvi

Practice Problem 2:
Solution:

CH-414|Chemical Plant Design| Dr. Syed A. Taqvi

Practice Problem 3:
2.27 m3/h water at 320 K is pumped in a 40 mm ID pipe through a distance
of 150 m in a horizontal direction and then up through a vertical height of 10
m. In the pipe there is a control valve for which the friction loss may be
taken as equivalent to 200 pipe diameters and also other pipe fittings
equivalent to 60 pipe diameters. Also in the line is a heat exchanger across
which there is a loss in head of 1.5 m of water. If the main pipe has a
roughness of 0.2 mm, what power must be supplied to the pump if it is 60
per cent efficient?

Reference: Coulson & Richardson’s “CHEMICAL ENGINEERING” VOLUME 1

CH-414|Chemical Plant Design| Dr. Syed A. Taqvi

Practice Problem 3:
Solution: Re
= 0.004 ( From Stanton’s Diagram)
e u 2
Relative roughness: = 0.005
d Equivalent length of pipe = 170.4 m
3 2
Viscosity at 320 K : 0.65 x 10 N s/m
Re l u 2
hf = 4 2 = 1.74 m
D 2
u d g
Area for flow : =1.26 x 103m 2
4 Total head to be developed = 13.24 m
Q
Velocity : = 0.50 m/s Mass throughput = 0.63 kg/s
A
Re = 30770
CH-414|Chemical Plant Design| Dr. Syed A. Taqvi
Practice Problem 3:
Power required = 81.8 W
For the 60 % pump efficiency =
 81.8 
  = 136.4 W or 0.136 kW
 0.6 

CH-414|Chemical Plant Design| Dr. Syed A. Taqvi