Plant and Process Design: Detailed Pump System Design Project

This assignment presents a comprehensive design of a pumping system to transfer raw water from Reservoir A to Reservoirs B and C, incorporating multiple pumps and control valves. The solution includes a detailed system schematic with considerations for pipe and fitting materials, expansion joints, and drain points. It outlines recommended flow velocities, calculates pipe diameters and associated head losses for suction and discharge lines, and determines expected pump operating points for different modes. The project addresses pump selection based on manufacturer specifications, performance curves, and system resistance curves. It also analyzes control valve settings and NPSH safety factors to prevent cavitation. The assignment covers all aspects of the pump design, including calculations, valve settings, and pump selection.

Running head: THE DESIGN OF A PUMP SYSTEM 1
Pumping system design
Firstname Lastname
Name of Institution

THE DESIGN OF A PUMP SYSTEM 2
Task 1
A detailed system schematic for MODE (I)
Important notes on the design above
D is taken as the reference point for all the points A, B, C and D. the pipes and fittings used in
the design are galvanized. Long radius flanges matching the pipe size are used as elbows
Line A- Pump Station
1. Non critical control valves: CV1 - CV2 -CV3
Bypass line for ISV1, gate valves to fully isolate Reservoir A from the system for maintenance.
Close to reservoir to prevent losses while draining the system
Expansion Joint: EXP1
This joint will give room for both thermal and seismic expansion that may occur in the pipe line
A-P. It is placed towards the end of longer pipe for optimal effect.
Drain point D1

THE DESIGN OF A PUMP SYSTEM 3
This will form the low point drain for the pipe line A-P in certain scenario, draining may be
done for maintenance. This drain point is located at the lowest point to allow complete drainage
for line A-P.
Suction Isolation valve, ISV1
Butterfly suction isolation valve (as per design requirements), to regulate NPSHA. Located close
to reservoir for ease of maintenance
Non critical control valves, CV4
Valve CV4 is an optional valve in this case. It served in maintenance of drainage line since it is
the global isolation of line A-Pump station. Pump isolation valve can serve similar purpose as
this valve.
Series arrangement for the Pump Station in obtaining volume flow rate
Critical valves CV5-CV6-CV7
The main role of these valves is to reduce waste volume circulation and steadfast in circulation.
They are standby and placed at the inlet of each line.
Expansion joints EXP2-EXP4
Expansion joint to allow for expansion in pumping lines. Also provide vibration damping
Strainers S1-S3
These strainers placed just before pump inlet play a role in removing contaminants before
entering pump.
Flow gauges, FG1-FG3

THE DESIGN OF A PUMP SYSTEM 4
These flow gauges plays a role of determining velocity head and flow heads which ensures that
the NPSHA > NPSHR. They are installed at the inlet having no loss after to ensure accuracy in
readings.
Pressure gauges, PG1-PG3
They are used to determine the pressure heads and just like the flow gauges, they assist in
ensuring that NPSHA>NPSHR. They are installed at the inlet having no loss after to ensure
accuracy in readings.
Task 2
Recommended flow velocity ranges
For suction line, the recommended velocity ranges from 1 m/s range 2 m/s while velocity range
for the delivery lines is 1.5 m/s to 3 m/s
The equation below is applied to represent the initial estimate on the requied diameter based on
volume of the flow rate
Vn represents the nominal pipe flow rate m^3/s, Dn is the estimated pipe diameter m while Vrec is
the recommended flow velocity in the section of the pipe measured in m/s
Pipe
Suggested
Velocities
Projected
Pipe
Diameter
A-P (Suction Line) 1.80 m/s 450 mm
P-D (Main Discharge Line) 2.5 m/s 350 mm
D-B (Branch line) 2.5 m/s 150 mm

THE DESIGN OF A PUMP SYSTEM 5
D-C (Branch line) 2.5 m/s 350 mm
Pipe specification and resulting flow velocities
Pipe
Specificatio
n DN
Outer
Diameter
Pipe
Thickness
Inner
diameter
Area of
flow in
m2
A-P 450 457.0 6.30 444.40 0.155
Pump line 300 324.0 4.55 314.90 0.078
P-D 350 355.6 6.35 342.90 0.092
D-B 150 160.0 8.20 143.60 0.016
D-C 375 350.0 10.00 340.00 0.089
Computing Associated head losses
Head losses = losses due friction on pipe wall + Losses due to pipe fittings
Losses due to friction is given by the equation below
where H, is the head loss in (m), D is the pipe diameter, v is the fluid velocity, g is the
gravitational acceleration taken to be g= 9.81 m/s2 with f representing the coefficient of friction
given as

THE DESIGN OF A PUMP SYSTEM 6
Head loss summary for line A-P
Rate of Flow 250 L/s
Diameter of the pipe 450 mm
Length 200
Reynolds No. 724173
Coefficient of friction 0.014
Total K 7.72/5.06
Overall Head loss 2.45 m
Head loss summary for line P-D
Rate of Flow 250 L/s
Diameter of the pipe 350 mm
Length 400
Reynolds No. 800005
Coefficient of friction 0.012
Total K 10.5
Overall Head loss 4.98 m
Head loss summary for line D-B
Rate of Flow 50 L/s
Diameter of the pipe 150 mm
Length 1100 m
Reynolds No. 310000
Coefficient of friction 0.017
Total K 5.50
Overall Head loss 11.50 m
Head loss summary for line D-C
Rate of Flow 200 L/s
Diameter of the pipe 350 mm
Length 450 m
Reynolds No. 780593
Coefficient of friction 0.017

THE DESIGN OF A PUMP SYSTEM 7
Total K 12.41
Overall Head loss 7.80 m
Task 3
Expected pump operating points for MODE (I) & (II) and pump performance and system
resistance curves
Valve setting for TV2 in modes III
Head at the pump = HD1 + Frictional Losses P -D = 53.59 +5.2 = 58.79 meters
Hence the drop-in pressure at TV2 = 58.79-5.2 -42 = 11.6 m
Pumps selection
The properties of the pump to go for are as shown in the table below
Manufacture Thompson Kelly and Lewis
speed 1450 rpm

THE DESIGN OF A PUMP SYSTEM 8
NPSHR 4.5 meters
Impellor Material Stainless Steel
model
Hydro Titan 250 x 250 - 350
H.T
Required impellor Diameter 400 mm
Power Input 75 kW
Original impellor size 400 mm opened
Expected Efficiency 80% @ 65 m
System Curves
The system takes the curves nature which follows the following equation
The combined system curve are as follows
Combined Pump curve becomes

THE DESIGN OF A PUMP SYSTEM 9
Combined pump curve
Task 4

THE DESIGN OF A PUMP SYSTEM 10
The amount of the main suction isolation valve to be throttled in MODE (I) & (II) in order
to match an NPSH safety factor of 1.15 for the pumps
To prevent cavitation, the values of NPSHA must be greater than NPSHR
Tas
k 5
Pump operating points, system resistance curves and control valve settings
Control Valve is as shown

THE DESIGN OF A PUMP SYSTEM 11
References
ASHRAE. (2010). 2008 ASHRAE Handbook: Heating, Ventilating, and Air-conditioning
Systems and Equipment. ASHRAE.

THE DESIGN OF A PUMP SYSTEM 12
Cengel, Y., & Cimbala, J. (2013). Fluid Mechanics Fundamentals and Applications: Third
Edition. McGraw-Hill Higher Education.
National Renewable Energy Laboratory (U.S.), U. S. (2011). Improving Pumping System
Performance: A Sourcebook for Industry, Second Edition. United States. Department of
Energy.
Pump Industry Australia Inc. (2013). Australian Pump Technical Handbook (5th ed.). Pump
Industry Australia Incorporated.
Sustainability Victoria. (2009). Energy Efficiency Best Practice Guide Pumping Systems.
Sustainability Victoria, 1-35.