FLUID FLOW SYSTEM DESIGN

Submitted by:
***********

Submitted to:
Prof. Rex B. Demafelis
Professor-in-charge

20 January 2003

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Problem Statement:
Design a fluid flow system, from a source near the new CEAT building to the
Chemical Engineering environmental laboratory that will deliver 100L per min of sodium
hydroxide (NaOH) solution. The storage tank will be centered on a specified location right
outside the chemical engineering laboratory. The line pressure from the pump to the tank is
100 psi while the outlet pressure from the tank is 2 atm.
Given: Q = 100 L/min
Outlet pressure= 2 atm = 29.4 psi
Fluid: 0.5 kg NaOH/kg solution
Line Pressure from pump to storage tank: 100 psi
Calculations:
Material for Construction:
From table 28-2, p28-30 of Perrys 7 th ed the suitable material to handle caustic and mild
alkalies is stainless steel. In this case, use austenitic stainless steel 18Cr, 8 Ni-type.
Assume a working temperature of 35 oC.
From Table 1 and Table 2, interpolate to get the density and viscosity of 0.5 kg NaOH/kg
solution at 35 oC.
Density of 0.5 kg NaOH/kg at 35oC.
(40-30)/(40-35) = (1510.9-1518.1)/(1510.9- )
= 1514.5 kg/m3
=1514.5 kg

2.2lb 0.3048m
lb 3

= 94.34890
m
ft
ft
kg

Viscosity of 0.5 kg NaOH/kg at 35oC.

(40-30)/(40-35) = (25.50-47.70)/(25.50-)
4
1Pa
6.72 x10 lb / ft s

0.001Pa s
1000mPa

= 0.0245952lb /( ft s )

= 36.6mPa s

Tank Sizing:
Let us assume that the storage tank should supply NaOH for a maximum of 16
hours in case of emergency (brownout, maintenance).
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Tank Volume:
V = 100

1m 3
L 60 min
3

(16hrs )
1000 L
= 96m
min hr

According to our handout, p. 29, tanks with volume more than 1.9m 3 must only be filled
90%, therefore:
V =

96m 3
= 106.6666667m 3
0 .9

From Table 1, p. 29 of handout, the height of a tank having a volume of 106.6666667m 3 is

5.5m or 18ft.
Calculating for the Actual Diameter of the tank:
V =
D=

D 2 H
4
4V
=
H

4(106.6666667 m 3 )
1 ft

= 4.969218305m

(5.5m)
0.3048m

D = 16.30320966 ft

Maximum height of liquid:

4V
4(96 m 3 )
1 ft

H =
=
= 16.24015748 ft
2
2
D
( 4.969218305m) 0.3048m

Tank Design:
Shell Design: (by one-foot method)
For tanks, use an allowable stress of 15000 psi as stated by the American Water
Tanks Association. Also, assume a zero corrosion allowance.
Bottom shell (first course):
2.6 D( H 1)G
t =
+ CA
S

2.6(16.30320966 ft )(16.24015748 1) ft (1.5145)

15000 psi
t = 0.065224977in.
t =

From table 1 of handout the minimum thickness of shell is 0.1875 in. (API 650)
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Top shell (second course):

2.6(16.30320966 ft )(7.24015748 1) ft (1.5145)
15000 psi
t = 0.026706687in.
t =

We also use the minimum shell thickness of 0.1875in. for the top shell.
Shell Design (by Variable point method)
Solving for the bottom course thickness,

0.463D
t1 =
1.06
H

HG
S

2.6 HDG

+ CA

where: D(tank diameter in ft)=16.30320966 ft

H(liquid height in ft)=16.24015748 ft
G(specific gravity of liquid=1.5145
S(allowable stress in psi)=15000 psi
t(required thickness in inches)
CA(corrosion allowance)=0

0.463(16.30320966 )
t1 =
1.06
16.24015748

t1 = 0.072366908in

(16.24015748)(1.5145)
15000

2.6(16.24015748)(16.30320966)(1.5145)

15000

From Table 6 of handout page 41, we should use the minimum thickness of shell which is
0.1875 in.
In solving for the second or top course thickness, we need to check the value of
h1 / rt1 to determine the equation to use for t2.

h1 (height of first course in inches)=9ft(12in/1ft) =108 in

r (radius of shell in inches)=97.81925796 in
t1 = 0.1875 in
h1
rt1

= 25.21801725

since h1 / rt1 is greater than 2.625, t2 = t2a. Equation 6 from the handout shows how to
solve for the value of t2a.

t 2a =

2.6 D( H 12X ) G
+ CA
S

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from which X is equal to either of the three (whichever is lowest):

X 1 = 0.61 rt u + 0.32Chu
X 2 = Chu
X 3 = 1.22 rt u

where:
C=

K ( K 1)

1+ K K
tL
K =
tu

For the first trial we use the following values:

hu (height of upper shell in inches) = 86.88188976 in
tL (thickness of lower shell in inches) = 0.1875 in
tu (thickness of upper shell in inches) = 0.026706687 in
The value for tu was assumed based on the result of the one-foot method.
K =
C=

0.1875
= 7.020713576
0.026706687
7.020713576 (7.020713576 1)
1 + 7.020713576 7.020713576

= 0.813816688

X 1 = 0.61 (97.81925796)(0.026706687) + 0.32(0.813816688)(86.88188976) = 23.61184166

X 2 = (0.813816688)(86.88188976) = 70.70593178
X 3 = 1.22 (97.81925796)(0.026706687) = 1.971886987

The value of X3 will be used in equation since it has the lowest value.

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t 2a

) ]1.5145
2.6[16.30320966( 7.24015748 1.971886987
12
=
= 0.030283222in
15000

Trial 2
K =
C=

0.1875
= 6.191547126
0.030283222
6.191547126 (6.191547126 1)
1 + 6.191547126 6.191547126

= 0.787381751

X 1 = 0.61 (97.81925796)(0.030283222) + 0.32(0.787381751)(86.88188976) = 22.94083686

X 2 = (0.787381751)(86.88188976) = 68.40921456
X 3 = 1.22 (97.81925796)(0.030283222) = 2.099776412

The value of X3 will be used in equation 6.

t2a =

2.6[16.30320966( 7.24015748
15000

2.099776412
12

) ]1.5145

= 0.03023761in

We also use the minimum shell thickness of 0.1875 in. for the top shell.
Distance between stiffeners:
From equation 8 of the handout
100t
H = 6(100t )

100(0.1875in.)
H = 6(100)(0.1875in.)
16.30320966 ft

H =138.7537598 ft

Stiffener is not needed since the height of the tank is 18 ft only.

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Annular Plates: (not less than 24 inches)

L=

390t b
GH

390(0.25in)
1.5145(16.24015748 ft )

L =19.65960821in.

Still use 24 in for the annular plates.

Bottom Plate:
From table1, handout: use minimum thickness of 0.25 in
Roof Design:
R2 = 0.0625Et2 /P
P= 20.4 psf
E= 29x106
t = [(16.30320966/2)2(20.4psf)/(0.0625)(29x106)] 1/2
t = 0.027347598 in
From Table 6 of the handout, p. 41, the minimum roof thickness is 0.1875 in.

Pipe specification:
Calculating for the minimum diameter of pipe:
Dmin for clean fluid is
1

Dmin

1.03w 2
=
.
1
3

= 100 L min 94.34890 lb

= 19.99139735kips / hr

Dmin =

60 min
1 ft 3

= 19991.39735 lb hr

3
ft 28.31685 L
1
hr

1.03(19.99139735kips / hr )1 2
13

94.34890 lb 3
ft

= 1.01161017in.

Use 1.25 in. schedule 40 iron pipe.

From Table 1 of the hand-out: Do actual = 1.66 in, Di actual = 1.38 in, D Nominal = 1.25 in
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t=

1.66in. 1.38in.
= 0.14in
2

Checking if the pipe thickness fits the minimum thickness required:

The allowable stress for stainless steel pipe (18% Cr, 8% Ni, TP304) according to
Table10-49, page 10-110 of Perrys 7th ed. is 20000 psi.

( P + 30S ) D
2.3ts S
p=
t=
D 30
2.3s
20000 psi

100 psi +
(1.66in )
30

t=
= 0.027666666in.
2.3(20000 psi)

Adding an allowance for threading,

t = 0.027666666in. +

0.80
in. = 0.097231884in.
11.5

Therefore, the 1.25 in schedule 40 iron pipe can withstand the pressure.
Outlet side: (see the layout for reference)
The pipe will be connected from the bottom of the tank and will be submerged 2
feet below the ground. A globe valve will be used at the end of the pipe to control the flow
rate. A gate valve will also be used along the vertical pipe below the tank.
The maximum length of a standard pipe is 20 feet; therefore couplings will be
needed in the flow system. If failure in the pipes occurs after some time and repair is
necessary, the pipe will be cut and replaced by new one and unions to reconnect the system
will replace couplings.
Energy Balance:

Pb Pa Vb 2 Va 2 g
+ ( zb z a ) = F

+
g

c
c

The change in the height of liquid in the tank is very small. Consequently, we can
assume that the velocity of the fluid in the tank is zero.
Calculating the velocity at the pipe,

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Q
= =
A

1 ft

100 L / min

28
.
31685
L

= 339.9926258 ft / min 1 min = 5.666543764 ft

2
s
60 s
1.38

ft
12

Calculating for the Reynoldss number,

N Re =

.38
(94.34890lb / ft )( 5.666543764 ft / s )112
ft
3

0.0245952lb / ft s

= 2499.784497

If youll notice the Reynolds number is in transition state, it could be laminar or

turbulent. In this case, I preferred it to classified under turbulent in determining the friction
factor.
From figure 20.2, p. 543 of Foust 2nd ed, 1980, =0.54
From Table 6-1 Perry, p. 6-10, for commercial steel is 0.0457 mm.
/D=(0.0457mm/1.38 in)(1 in/25.4 mm) = 0.0013
Form Figure 6-9, p6-10 of Perrys 7th ed, obtain the Fanning friction factor, f.
f = 0.0125

Calculating for the friction losses,

4 fL
F =
+kf
D

2
v

2 g c

k-values from Table 6-4, p.6-18 of Perrys 7th ed,

1 globe valve = 6.0
5 900 elbow = 0.75

9 coupling = 0.04
1 gate valve=0.17

From Appendix C-2c, p. 719 of Foust 1980,

Inward projecting pipe

k=0.78

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ft

5.666543764
4(0.0125)(177.2965879 ft + h)

m
F =
+ 6 + 0.78 + 5(0.75) + 9(0.04) + 0.17
(1.38 / 12) ft

lb ft
2 32.174 m 2

lb f s

= ( 0.216956969h + 43.98468175)

lb f ft

lbm

Substituting the values to the energy balance and calculating for the elevation of the tank,
14.7 psi 144 psf
Pb = 2atm

1atm 1 psi
Pa =1atm = 2116.8 psf

= 4233.6 psf

4233.6lb f / ft 2 2116.8lb f / ft 2
94.34890lbm / ft 3

2
lb f
(
5.666543764 ft / s )
( 5.905511811 ft h 16.2415748 ft ) =
+
+
1
lbm
2( 0.54 ) 32.174 lblb sft

m
f

= 43.98468175 + 0.216956969h

h = 72.80568687 ft

The height suggests 4 couplings; we will use one gate valve as a coupling to save us
from buying another coupling and the need to cut the pipe in order to accommodate the gate
valve. Note that in solving for the frictional losses, these additional fittings were already
accounted for. I already computed the height and then add the additional fittings needed on
a scratch.
Pump side: (see the layout for reference)

Pb Pc Vb 2 Vc 2 g
+ ( zb z c ) = F W f

+
g

c
c

Since the points considered are both vented to atmosphere, the pressure term can be
neglected. Also, take the velocity of the reservoir to be zero since the change in height of
the liquid is too small compared to the whole reservoir.
The fluid bed was found out to be 14.6 meters below the ground and the bed
height is about 50 meters. Using the obtained data of the fluid bed, the pipes will be
designed to extend 50 ft below the fluid surface.
A foot valve will be installed at the end of the extended pipe in the fluid source so
that there will always be fluid in the pipes even if the pump is turned off. The pump will
find difficulty in starting up if there is no foot valve. A check valve will be connected right
after the pump so that the liquid will not flow back if the pump is turned off or in case of
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brownouts. A globe valve will also be connected after the check valve to allow passage of
the fluid and to control its flow. A gate valve will also be placed just before the fluid enters
the tank.
.
k-values from Table 6-4, p.6-18 of Perrys 7th ed,
1 globe valve = 6.0
1 gate valve = 0.17
1 check valve = 10.0

69 coupling = 0.04
8 900 elbow = 0.75
1 foot valve = 15

From Appendix C-2d of Foust 1980, p. 719

Projecting pipe exit

k=1.0

Calculating for the friction losses,

2
4 fL

F =
+kf
D
2g c

ft

4(0.0125)(1448.302322 ft )
5.666543764 s
=
+ 1 + 6 + 10 + 0.17 + 15 + 8(0.75) + 69(0.04)
1.38

12 ft
2 32.174 lbm ft

lb
s
f

= 334.6433944

lb f ft

lbm

Substituting values in the energy balance and calculating for the actual work,
2

5.666543764 ft
s
lb

+1 f
{[(72.80568687 2) + (16.24015748)] (47.9)} ft =
lbm
lbm ft
2(0.54)(32.174
)
lb f s 2
334.6433944

lb f ft

WF = 470.5133147

lbm

WF

lb f ft

lbm

Computing for the actual hp,

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P = W f

= Q

1 ft 3
1hp
3 1 min
P = 470.5133147 ft lb f / lbm (100 L / min )
28.31685 L
94.34890lbm / ft 60 s 550 ft lb / lb

f
m
P = 4.750615471hp

Use a radial pump with a power requirement of 5 hp.

Summary:
Material for construction:
Austenitic stainless steel (18% Cr, 8% Ni , TP304)
Tank Specifications:
Height = 5.5 m or 18ft
Diameter = 16.30320966 ft
Elevation = 72.80568687 ft
Shell thickness = 0.1875 in.
Annular plate length = 24 in.
Bottom plate = 0.25 in
Roof thickness = 0.1875 in
Pipe Specifications:
Schedule 40
Nominal diameter = 1.25 in.
Actual outside diameter = 1.66 in.
Actual inside diameter = 1.38 in.
Pipe Connectors:
Couplings = 78
90 elbow = 13
Gate valve = 2
Globe valve = 2
Foot valve = 1
Check valve = 1
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Pump Specification:
Radial Pump
Power requirement = 5 hp

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