Fall 2009 CE154 1

Pipe System Design

CE154 - Hydraulic Design
Lecture 7
Pump System
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Pump Terminology
Pump head (dynamic head) H
Pump discharge Q
Pump speed n
Pump power P


Centrifugal Pump
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Rotary Pump
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Reciprocating Pump
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Pump Terminology
Power P













Motor
efficiency q
m
Pump
Efficiency q
p
Q, H
Fall 2009 CE154 8
Pump Terminology
Pump Output (Water) Power (Q in gpm, H in
ft, s is specific gravity and dimensionless, and
P in horsepower)


Pump Input (Brake) Power

3960
QHs
P
w
=
q
p
QHs
bhp
3960
=
Fall 2009 CE154 9
Pump Terminology
Electric Motor Power




Typically motor efficiency is approximately
98%

q q
m p
QHs
mhp
3960
=
Fall 2009 CE154 10
Pump Terminology
Single or Double suction pump
Single or multiple stage pump

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Pump Specific Speed



Q is gpm per suction, n is rpm, H is ft per stage
Pump Type N
s
(US unit)
Radial Pump 500-4200
Mixed flow Pump 4200-9000
Axial flow Pump 9000-15000
H
Q
N
n
s
75 . 0
5 . 0
=
Fall 2009 CE154 12
Pump Performance
Variable-Speed pumps may be
desirable when different operating
modes require different pump head or
flow
Homologous laws
Q
1
/Q
2
= n
1
/n
2

H
1
/H
2
= (n
1
/n
2
)
2

P
1
/P
2
= (n
1
/n
2
)
3



Pump Performance Curves
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Pump Terminology
Static Lift elevation difference
between pump centerline and the
suction water surface. If the pump is
higher, static lift is positive. If pump is
lower, static lift is negative.
Static Discharge elevation difference
between the pump centerline and the
end discharge point. If pump is higher,
static discharge is negative.
Total Static Head sum of static lift
and static discharge.
Fall 2009 CE154 15
Pump Terminology
Shutoff Head head at 0 flow
Operating point the point where the
pump curve and the system curve
intersect. A system curve is a curve
describing the head-flow relationship
of the pipeline system.

Q
b a H
2
+ =
Fall 2009 CE154 16
System Curve
friction losses
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Operating Point
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Pump Terminology
Net positive suction head (NPSH)
- to ensure that water does not vaporize at
the pump impeller tip
- NPSH available = available suction head +
atmospheric pressure vapor pressure
suction head loss = determined by local
condition
- NPSH required = characteristic of and
provided by pump curve

h h h h NPSH
s vp s atm A
A + =

Fall 2009 CE154 19
Example (p. 10.3 Mays HDH)


Fall 2009 CE154 20
Atmospheric Pressure
At mean sea level,
1 atomospheric pressure = 14.69 psia
= 1.03 kg/cm2
= 760 mm Hg


El.(ft) 0 1000 2000 4000 6000 8000
Patm
(psia)
14.69 14.17 13.66 12.69 11.8 10.9
Fall 2009 CE154 21
Vapor pressure
Vapor pressure of water at atmospheric
pressure

T
(F)
32 40 50 60 68 80 90
P
v

(psia)
0.089 0.112 0.178 0.256 0.339 0.507 0.698
T
(F)
100 120 140 160 180 200 212
P
v

(psia)
0.949 1.69 2.89 4.74 7.51 11.53 14.70
Fall 2009 CE154 22
Pipe System Design
Determine system curve
- identify all loss-incurring elements
including friction, transitions, fittings,
valves and other special equipment in
the system (use Darcy-Weisbach
equation to compute friction loss)
- identify suction and discharge
conditions

Fall 2009 CE154 23
Design Scenario Ex. 8-1
Need to deliver water from Santa
Teresa Water Treatment Plant at
elevation 300 ft to Cisco Power Plant at
elevation 330 ft. The maximum flow
demand is 200 cfs. Design pipe size and
regulating devices for operation.
Basic design approach
- consider steady-state, governing case
- design pipe size and control equipment
- check transient condition to verify
pipe pressure class
Fall 2009 CE154 24
Example 8-1
1. Prepare a list of available design data:
- Design discharge 200 cfs
- Suction water elevation El. 300 ft
North Am. Vertical Datum (NAVD88 )
- Discharge water elevation El. 330 ft
NAVD88
2. Prepare a list of data requirements:
- Topographic maps to route pipeline
- Right of way maps
- Utility and road crossing maps
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Example 8-1
- Select a pump station site to set
preliminary pump elevation:
-- assume 2 Pumps set at El. 290 ft
-- station design includes 40 ft of
pipeline, 4 isolation valves and 2 pump
discharge valves
- No other information on discharge site
is needed (for hydraulic design), other
than the maximum tank level at 330 ft.
Fall 2009 CE154 26
Example 8-1
3. Assume that we have selected a route
that results in a pipeline 8.0 miles long,
and the fittings include
- 80 bends of 90,
- 25 bends of 45,
- 10 butterfly valves for isolation
4. Determine pipe diameter
- rule of thumb maintain operating
velocity at 6-8 ft/sec (Ah V
2
,
consider economic analysis later)
Fall 2009 CE154 27
Example 8-1 Pipe Sizing
Design maximum discharge Q = 200 cfs
assume V = 8 ft/sec
A = 200/8 = 25 ft
2

D = 5.64 ft = 67.7 inches
Say D = 72 inch why?
A = 28.27 ft
2

V = 7.1 ft/sec
Next, determine pipe material. For this
size, steel and reinforced concrete
pipes are available. Say RCP.
Fall 2009 CE154 28
Example 8-1
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Example 8-1 Friction loss
From roughness chart, for 72 concrete
pipes, in the mid roughness range, i.e., not
new but not seriously corroded,
e/D = 0.0005 f=0.017
From equation for turbulent rough flows,



f = 0.017 O.K.
|
.
|

\
|
=
D
e
f
log 2 14 . 1
1
Fall 2009 CE154 30
Example 8-1 Friction loss
When the pipe is significantly corroded,
the chart shows that
e/D = 0.0017 and f=0.023
When new pipe, the chart shows
e/D = 0.000165 and f=0.0135
Use the mid roughness values for
design, and use the new pipe and rough
pipe values to check the system design
to ensure operability.
Fall 2009 CE154 31
Example 8-1 Friction loss
Compute friction loss:
Ah = f L/D V
2
/2g
= 0.017 x 8 x 5280 / 6 x V
2
/2g
= 119.7 V
2
/2g
= 119.7 x (7.1)
2
/2/32.2
= 93.7 ft
Compute minor losses:
Size the butterfly valves:
Use Val Matic valve data
Fall 2009 CE154 32
Example 8-1 Valve data
Val Matic butterfly valve data


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Example 8-1 Valve sizing
Q=C
v
(AP)
1/2
Q = 200 cfs x 448.8 gpm/cfs = 89760 gpm
Considerations:
- use the smallest size of valve that can
pass the design flow with acceptable head
losses


Valve size (in)
Fully-open Q (gpm)
AP (psi)
72 266500 1
42 87100 1
54 144000 1
Fall 2009 CE154 34
Example 8-1 Valve loss
For this example, lets try 72 valves.
At 266500 gpm, the valve incurs 1 psi
of loss.
In terms of

Q = 266500 gpm = 593.8 cfs
A = 28.27 ft
2
, V = 21.0 fps,
Ah = 1 psi = 2.31 ft, k
v
= 0.337
At 200 cfs, V=7.1 fps, Ah = 0.26 ft per
valve
g
k h
V
2
2
= A
Fall 2009 CE154 35
Example 8-1(Val Matic BFV)

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Example 8-1 Minor loss
Compute 90 bend losses:
Assume r/D=2, from Slide 34 of last
lecture, k
b90
= 0.19
There are 80 bends at 90.

Compute 45 bend losses (25 of them):
Assume r/D=2, k
b45
= 0.1 (Crane TP410).
There are 25 bends at 45
Fall 2009 CE154 37
minor loss Reference
This web link provides a few pages from
the Crane Co. technical paper 410
(selling for $35 at Crane Co.) for
calculating minor losses
http://www.lightmypump.com/help16.ht
ml
Fall 2009 CE154 38
Example 8-1 System head loss
Compute total head loss:








Since we have suction piping as well, compute
loss in the suction pipe
g
g
g D
L
f
g g D
L
f
V
h
V
h
V
k n k n k n h
V
k n k n k n
V
h
l
l
b b b b v v l
b b b b v v l
2
8 . 140
2
) 1 . 0 25 19 . 0 80 337 . 0 10 7 . 119 (
2
) (
2
) (
2
2
2
2
45 45 90 90
2
45 45 90 90
2
=
+ + + =
+ + + =
+ + + =
Fall 2009 CE154 39
Example 8-1 Pipe sizing
Assume the pump
station has 2 pumps.
To have the same
velocity in the pipes,
the pump discharge
and suction pipe
diameter is 54.

Additionally, 1 pipe
bifurcation and 1
combining to
contribute to minor
losses
54 9 . 50
2
1
72
1
1
2
1
2
1
~ =
=
=
D
D
A
A
D
D
Fall 2009 CE154 40
Example 8-1 Pump Station
Loss
Losses at pump station:
f = 0.0175 from Slide 32, Lecture 8
Ah
f
= (0.0175 x 40 / 4.5)V
54
2
/2g
= 0.16V
54
2
/2g
Bifurcation loss: k
bi
= 0.3 V
54
2
/2g
Combining loss: k
cm
= 0.5 V
54
2
/2g
Valve loss: k
v
= (0.337 x 2 +3.0) V
54
2
/2g
Total loss = 4.63 V
54
2
/2g
Fall 2009 CE154 41
Example 8-1 System
Schematics



El. 300 ft
El. 290 ft
El. 330 ft
H
p
Fall 2009 CE154 42
Example 8-1 System Curve
Total static head
Hst = 330-300 = 30 ft
Losses
pump station loss + pipeline loss
= 4.63 V
54
2
/2g + 140.8 V
72
2
/2g
= 4.63 Q
54
2
/(2gA
54
2
) + 140.8 Q
72
2
/(2gA
72
2
)
= 4.63 Q
72
2
/(8gA
54
2
) + 140.8Q
72
2
/51483.8)
= 4.63Q
2
/65159.2 + 140.8Q
2
/51483.8
= (0.000071 + 0.002734)Q
2

= 0.002805Q
2
Fall 2009 CE154 43
Example 8-1 System Curve
System Curve
H = 30 + 0.002805 Q
2







H
(ft)
30. 31.8 37.0 45.8 58.1 73.8 93.1
115.9 142.2 172.0
Q
(cfs
)
0 25 50 75 100 125 150 175 200 225
Fall 2009 CE154 44
Example 8-1 System Curve
The Q in system curve is the total flow
Since we have 2 pumps, each pump puts
out half of the total Q
In this case, need to construct the 2-
parallel-operating pump curve by
doubling the flows
Plot the system curve over the pump
curve to determine the pump operation
point

Fall 2009 CE154 45
Example 8-1 Pump Selection












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8-1 Pump Operating Point
Select 17.57 impeller

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Ex. 8-1 Pump operating point
For new and old pipe conditions, revise
system curves and determine if the pump
can operate at these limits. In new pipes,
pump may run-out (fall off the far end of
the pump curve), or not meeting the higher
NPSH requirement.
In really old pipes, pump may not be able
to deliver the required flow rate.
Fall 2009 CE154 48
Ex. 8-1 New Pipe Operation
In this case, new pipe f=0.0135 instead
of 0.017. Friction loss coefficient
becomes 116.2 instead of 140.8. System
curves becomes
H = 30 + 0.002326Q
2
Fall 2009 CE154 49
Example 8-1 New pipe
condition
Fall 2009 CE154 50
Ex. 8-1 Pump Suction Design
Verify NPSH
A
meets NPSH
R

Assume average temperature of 68F,
hatm = 14.53 psia, interpolated from Table on
Slide 18
hv = 0.339 psia
hs = 300-290 = 10 ft
Ahs = 4.63 V
54
2
/2g = 4.63 (6.29)
2
/64.4 = 2.84 ft
NPSH
A
= (14.53-0.339)x2.31 + 10 2.84 = 39.9 ft
NPSH
R
= 7 ft from pump curve OK


h h h h NPSH
s vp s atm A
A + =
Fall 2009 CE154 51
Example 8-1 System HGL




El. 300 ft
El. 290 ft
El. 330 ft
H
p
Normal operation HGL
Pipe
Pressure
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Example 8-1 Steel Pipe design
Internal pressure p




Cutting the steel pipe in half, integrate
the pressure over the top inside surface,
the resulting force is supported by the
wall thickness at the two ends.


p
t
pipe diameter D
Fall 2009 CE154 53
Example 8-1 Pipe design
Total force on the top side




Stress on the wall


pD pr pr d pr = = =
}
2 cos sin
0
0
t
t
u u u
t
pD
s
2
=
Fall 2009 CE154 54
Steel Pipe Specifications
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Steel Pipe Specifications
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Concrete cylinder pipe
(Ameron)
Fall 2009 CE154 57
Example 8-1 Pipe design
Separate the pipeline into different
sections of similar design pressure level
and select pipe classes to match the
pressure requirements.
This pressure is the normal design
pressure.
Consider transient conditions to ensure
safe operation, e.g., pump start, pump
shutdown, valve closure, & loss of power


Fall 2009 CE154 58
Concepts of hydraulic
transients
Bulk modulus of elasticity




Change in density is accompanied by change
in pressure. This change is transmitted
through the system at the speed of the
elastic wave (sonic wave)

d
dp
E =
Fall 2009 CE154 59
Wave speed





E = elastic modulus of pipe wall
K = bulk modulus of water
e = pipe wall thickness
D = pipe diameter
= water density
a = wave speed
E
K
e
D
K
a
+
=
1

Fall 2009 CE154 60

Transient pressure
Joukowsky equation




AV = instantaneous change in velocity
a = wave speed in pipe
g = gravitational acceleration
AH = rise in head


g
V a
H
A
= A
Fall 2009 CE154 61
Transient considerations
Consider normal (pump start, valve
closure, etc.) and abnormal (power
failure, valve malfunction, etc.)
operations to determine pressure
fluctuations
Vacuum pressure and subsequent vapor
pocket collapse
Remedial actions
Fall 2009 CE154 62
Example 8-1 Discussion
Pump suction design requirement of
suction tank, suction pipe velocity,
function of isolation valves
Pipe system design proportions of
head loss elements, cost consideration,
right of way consideration
Pump selection multiple pumps vs.
single pump, power consumption
Fall 2009 CE154 63
Homework #8
Design a pipeline system to deliver a maximum
of 60 cfs of cooling water from Anderson
Reservoir with minimum water El. 300 ft to a
Calpine power plant 15 miles away at El. 250
ft. The minimum water pressure at the end
of the line should be 10 ft above atmospheric.
Ground elevation at the reservoir is El. 220
ft. Draw the pipeline profile with normal
operation HGL. Try the attached pump curve
to see if it is appropriate to use. If not, web
search for a pump curve or design your own.
Fall 2009 CE154 64
Homework #8