To properly specify the process requirements for G pump, the design engi- neer must explore the full range of operations the pump will be expected to perform. Considering ‘only the norma! operat- ing case could lead to disappointing perfor mance ai either higher- or lower-than-normai flowrates. Gone ce ee coche: Yay x“ ran en erg a) LASS Odea fared DESIGNING CENTRIFUGAL PUMP SYSTEMS Steven M. Fischer, The Badger Co. he full range of anticipated operations are analyzed in this method for designing centrifugal pump systems to properly determine pump and conirol-valve hydraulic requirements. The method can also help minimize overdesign by revealing the effects imposed by large contingencies in flowrates, even when control-valve differentials are miaimal ‘The process calculations ean be incorporated into a computer program, to ceshance the analysis and consistency of designs. By sul if actual pump- curve data and piping-and-equipment pressure Alternate ha ‘N= Norma fs A> Rated Fle in rated ditforential heed, 3% & ute Flow —* 24060 OS«*O0 ted eapacty, Figure 1 —Hoad vs. flow rolatonships lor three operating cases Usually, the allowable pressure drops in equipment and Piping are known or specified for the normal flow ease. To “develop the hydraulics forthe rated act alternate flow eases that are consistent with that for the normal flow ease, the designer needs some way of estimating the frictional pres sure lrops that correspond to the flowrates for the other cases. ‘The frictional pressure drop at a second flow condition ean be calculated if the drop is known at one flow condition, via a correlation based on the Darey equation: AP, = AP(V_/V,F Here, AP = vow pressure drop, and V = velocity oF flowrate, (Loy Qa 2 shi ‘The folowing aésumptions pertain to this equation: 1. Only the flowrates are different. Temperature and comm position remain the same. Tis eliminates the need to correct for changes in uid properties 2.Flow is turbulent throughout. 3. The frietion factor, f remains constant over the range of expected flowrates. Although f does vary with flow, the change is small, especially with well developed turbulent flow, relative to the effect that flowrate has on velocity, which is squared, 4, The frictional drop through equipment can be treated in the same manner as that through piping. ‘M48 cwewicas eNoIMEEING/FERRUARY 16 192 Figure 2— Generalized curve may be substituted for specie one flow would then be between 107% and 20% higher than the normal flow. A piping section from which piping branches off is re- ferred to as a common. Its frictional pressure drop is treated the same as that of any other pipe section. However, it contributes to the pressure drop of each of the branches. After the flowrates have been determined for the com mons and each branch—and, thus, for the pump — the frictional APs for each case can be adjusted via the Darcy- based correlation, when flows differ from the normal case. For pump selection, the design approach is to determine the rated head and flow requirements consistent with the ‘operating conditions of the normal case. Therefore, the procedure starts with the rated caleulations. Example — Column bottoms pump For the system shown in Fig. 8, determine the following: (a) pump head at rated flow; (b) eontrob-valve pressure drops in ‘each branch, for each ease; (e) net positive suction head ayailable (NPSH.A) at the rated flow; and (d) maximum pump discharge pressure ‘The following is given: a sketch of the pump system, sx¢ the flowrates occurring simultaneously in the branche. for each case (Fig. 3); estimated and allowable frietioal pressure drops for commons, branches and equipment a normal flow (Table 1); static heights and specific gravisP {ie 8 source and destination pressures (Table I), max ition losses = 64.7 + (185 x 0.15)/281~2 = 676 pia || Tan anowrable percent rise in head at shutoff; and fuid{/_ 3. Calelate the net positive suction head: NPSHA oie | vapor pressure atthe pumping temperature. suction pressure ~ vapor pressure = 67.6~ 647 = 29 pai (or The calculation procedure: R91. ancy cach operating case, determine the fowratesineach 4. Start the discharge calculations. The designe’ must {rant the commons, anda the pump, in order to beable | allow a minimal contol valve diferent forcack each ag Besa fe fetional AP terms for te diferet flowrate. | that the process can be conrad, even al ralad tone Pepe le the volumetric flows in the branches could vary | Typically, this diferent is based en's percentage of ss with temperature (one stream fow may be measured down- | frctional pressure drop (fr istane, 10-0 exchenge Fe Pag t ~ [ ! arene (De Shad ee Se iamey Gea ( FP aot P= 3.0 psi ‘OP = 12 psi | Fewer tr ich py hn nan ds pom aucniuntiwnocommswwammowae A Stream of a cooler, for example), branch flows should be Table |—Normal-case friconal pressure drops, psi ‘added on a weight basis to retain the material balance, After all the flows have been determined, correct the Branch 1 Branch? Branch frictional AP terms for the rated and alternate eases. For || tno ose anf 2 isa 80 example, caleuate the AP of the exchanger in Branch 2 at |] Sprecctangers 150 ° rated flow 150 gpm) ifthe allowable AP is 15.0 psiat normal || af; somes’ 10 10 10 flow (100 gpm). Thus, AP = 15.0 (150/100)? = 83.75 ps 1, namic To caleulate the AP in the suction line at rated fiow, || head (rin) 20 20 20 determine the weight flowrates in this line for each ease: ||P. heater Goss ° Flowrate,b/h = (60 Ib/h/gpm) x Sigpmysp.gr J Here,| | _4P. Comeron 5 szfers tothe branch numbers at contrbute tothe tal || NAT 30 zs flow. ; 500 (625)0.75) + (150x085) + | L_NO2 = & a (165X0.80)] = 362,625 Ib/h = 967 gpm. & di ZG Monnaze suction flow = 500 [(600\0:75) + (1000.88) | contol valve, or on an absolute minitnum AP (5-10 psi, for + (150X0.80)) = 289,000 Ib/h = 771 gpm, example). For these guidelines, the destination pressures are Rated-case suction line AP = 2.0 (862,625/289,00032 assumed to remain constant in all the eases. i * (7 First, the pump discharge pressure is calculated individ: Al fitional AP terms are corrected inthe same manner. {ually for each branch, aa follows: discharge pressure oe Note, however, that the correction factors for all the } destination pressure + static head + freon lones + branches, commons and pump sections are not necessarily | control valve AP. ean because ratios of ratedtonormal fowrates may | The branch having the highest discharge pressure wil be different, even for the same ease. govern the pump discharge pressure, with the control valve 2 gallate the ratedcase pump suction pressure, using pressure drops in the other branches being adjusted tof the the low liquid level (LLL) as the suction static height — ie, | pump discharge pressure. pump suetion pressure = souree pressure + static head = | For Branch I caleuate the total friction drop at rated (CHEMICAL ENGINEERING /PEBRUARY w, 107 149‘able ll — Given and calculated pressures and pressure drops in the thee branches forthe rated, normal and alleate ow cases Flow ease Rated Normal ‘ierate Branch No. Branch No. Branch No. Pressures 1 ee 1 on 1 2nd } , [aia pia 5 ear aT ear 7 aT } of State ea pt 60 80 80,0) sans + «|i tne loss, pel 31 Purp suction, psa ers“ } —Vapor pressure, psia | 647 } INPSHA. pala t) 29689) elven, pia a7 1471147 | State head, pal 1297 79 28 Line loss, pel s7eY (8/92 Coil valve AP, psi fie, \7e0 tas Exchanger AP, psi jo /|ss8/ 0 COriice AP, psi Saar | 23 12 Dynamic head AF. psi | (2 ps mir | Say) a1. as Heater AP, pst Sma Yio 8 } Common. APps | ar Yay 47 I Common No. 2 AP, psi 0 ‘\is2 192 I Pump discharge, psie Wid oa t914 “Sucton, pla 678 ump diferent pl 1258 Pump dierent 361 a3 flow: AP =78 +0416 +381 4781 447 + 0 = 953 psi Next caleulate the control-valve AP; the 20%, rather than | corrections to the friction terms are required. Caleulate the 10-psi minimum, rule governs here. Thus, the Branch 1 | normal suction pressure, using the static height at control valve minimum AP is 19.1 psi (953 psi x 20%). | normal liquid level (NLL). ‘The minimum pressure drops for the control valves in the { 8, Calculate the normal-case pump discharge press other branches are calculated similarly. *) Adjust the pump differential pressure for the lower pum In this example, Branch 1 governs the pump discharge | flow, and add this to the normal case pump suction press pressure. The frictional pressure drop in Branch 2 = 388 + | The normal pump flow = (771/967)100) = 79.7% of the a 388+ 22 +81 +0447 + 192 = 968psi. Therefore, the | pump flow. Using the 207 maximum head rise curve in -control valve AP would have been = 9638 x 0.20 = 19.4 psi, | 2, find the new pump differential at normal flow to be and the pump discharge pressure would have been = 968 + | higher than the rated differential: Normal differential » 194 +147 +79 = 1388 psia, However, because this is less | 1.082 x 1288 = 1940 psi. Therefore, the normal than 191.4 psia discharge pressure caleulated for Branch 1, | discharge pressure = 70.7 + 184.0 = 204.7 psia. the recalculated control valve AP for Branch2 = 1914-1474 9.Caleulate the control valve pressure drops of 19-968 = 72.0 psi. / branch for the normal flow case. Subtract the resped ‘The pressure drops of the remaining branches are ealeu- | destination pressure, static head and frictional pressured lated similarly. Note thatthe branch having the control valve | from the normal pump discharge pressure. ! with the highest APis not necessarily the governing branch. {- 10. Caleulate the hydraulics for the alternate case in <6, 5.Galeulate the pump diferential at rated floy. Pump |)same manner as for the normal ease, except for 39 2A" ) differential = 191.4 ~ 67.6 = 1238 psi (or 881 19. | correcting: the frictional pressure drops for differenes © 6.Caleulate the maximum pump discharge pressure, Add | flowrates, as was done for the rated-case flow. 2 the maximum pump differential pressure to the maximum | The calculations are suramarized in Table I ‘orresponding pump suction pressure. The maximum pump I-Mate, suction pressure wll occur when the vessel is being relieved, the liquid is at the high evel (HLL), and the pump is shut off (ey, maximum head and no fritional AP in the line). For this example, the maximum rise in head at shutoff is taken to be 2% of the rated head, and the source pressure at relief is taken to be 65 psig (79.7 psia), Therefore, the maximum suetion pressure = 797 + (185 + 60 + 20) (0.75)/281 ~ 0 = 888 psia. The maximum pump differential = 120 X 1238 = 1486 psi, and the maximum discharge pressure = 886 + 1486 = 237.2 psia The author Steven M, Fischer wat senior procs dap ‘crt er Engen when be haipin Petrcloum Co, resonable fr Oe is prewesing unis af th come SEES SUR be to ning Ber Ha eee apna prem gn eet i's Process Divoion. He bolls» BACK from Tulane Univern 150 cmucamcrmancrmeum nun Mkxiwe, CPs eo