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Copyright

1999 ITT Flygt AB

All Rights Reserved

ITT FLYGT AB MAKES NO WARRANTY, EITHER EXPRESSED OR IMPLIED, INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE REGARDING THESE MATERIALS, AND MAKES SUCH MATERIALS AVAILABLE SOLELY ON AN AS-IS BASIS. IN NO EVENT SHALL ITT FLYGT AB BE LIABLE TO ANYONE FOR SPECIAL, COLLATERAL, INCIDENTAL, OR CONSEQUENTIAL DAMAGES IN CONNECTION WITH OR ARISING OUT OF PURCHASE OR USE OF THESE MATERIALS. THE SOLE AND EXCLUSIVE LIABILITY TO ITT FLYGT AB, REGARDLESS OF THE FORM OF ACTION, SHALL NOT EXCEED THE PURCHASE PRICE OF THE MATERIALS DESCRIBED HEREIN. ITT Flygt AB reserves the right to revise and improve its products as it sees fit. This publication describes the state of this product at the time of its publication, and may not reflect the product at all times in the future. Limitations of Remedies REGARDLESS OF WHETHER ANY REMEDY SET FORTH HEREIN FAILS IN ITS ESSENTIAL PURPOSE, IN NO EVENT WILL FLYGT BE LIABLE TO YOU FOR ANY SPECIAL, CONSEQUENTIAL, INDIRECT OR SIMILAR DAMAGES, INCLUDING ANY LOST PROFITS OR LOST DATA ARISING OUT OF THE USE OF INABILITY TO USE THE SOFTWARE OR ANY DATA SUPPLIED THEREWITH, EVEN IF FLYGT OR ANYONE ELSE HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES, OR FOR ANY CLAIM BY ANY OTHER PARTY. SOME STATES DO NOT ALLOW THE LIMITATION OF EXCLUSION OF LIABILITY FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES SO THE ABOVE LIMITATION OR EXCLUSION MAY NOT APPLY TO YOU. IN NO CASE SHALL FLYGT'S LIABILITY EXCEED THE PURCHASE PRICE FOR THE SOFTWARE.

Adobe Trademarks Adobe , the Adobe logo, Acrobat, the Acrobat logo, Distiller, Exchange, and Postscript are trademarks of Adobe Systems Incorporated. Microsoft Trademarks Windows, Windows NT, Windows 95, Windows 98, Windows2000, DOS is trademarks of Microsoft Corporation. Other product names mentioned in this manual may be trademarks or registered trademarks of their respective companies and are hereby acknowledged."

User's Guide FLYPS 2.1 - English (FUS) P1

Contents
FLYPS 2.1 - Introduction 1
FLYPS 2.1 - A Pump System Design Tool................................1 New features in Version 2.1 .......................................................2

Getting Started

System Requirements .................................................................3 Contents ......................................................................................3 Installation ..................................................................................4 Standard Installation ........................................................4 Minimum Installation (Client) .........................................4 Customized Installation ...................................................5 Installing FLYPS 2.1........................................................6 Installing Acrobat Reader ................................................6 Network usage..................................................................7

General Instructions

Start FLYPS 2.1..........................................................................8 Component Description..............................................................9 Main window....................................................................9 Menu...............................................................................10 Toolbar ...........................................................................10 Case-Manager Toolbar...................................................10 Workflow..................................................................................11 Help...........................................................................................12 Tips & Explanations.................................................................12 Internet shortcuts ......................................................................13

Product Selection

14

Overview...................................................................................14 Browse ......................................................................................15 Search .......................................................................................16 Set Search Criteria..........................................................17 Search based on required flow and head .......................18 Search based on required flow and a specified pipe system.............................................................................18 Search based on alternative pipe systems ......................19
ii Contents User's Guide FLYPS 2.1

Search based on slurry calculation ................................ 20 Search based on energy consumption............................ 24 Pump list - description ................................................... 25

Product Data Presentation

27

Display Product data ................................................................ 27 Display pump curve and duty points ............................. 29 View Dimensional Drawings ................................................... 30

Pump System Analysis

32

Overview .................................................................................. 32 Pipe system design ................................................................... 32 Head loss calculations.............................................................. 33 Duty Analysis........................................................................... 35 Performance curves........................................................ 36 Duty conditions.............................................................. 37 Life cycle cost analysis ............................................................ 38 VFD - Analysis......................................................................... 43 Pump Performance......................................................... 44 Pump Perf. vs. Freq. (Performance versus Frequency) 46 Power vs. Freq. (Power versus Frequency) .................. 47 Power vs. Flow (Power versus Flow)............................ 48 Specific Energy.............................................................. 49

Pump Station Design Printouts

50 52

Sump Volume Calculation ....................................................... 50

Print Pump Performance Curve ............................................... 52 Print Outline Dimensional Drawings....................................... 54 Print Rating data....................................................................... 56 Print System Analysis Reports................................................. 56 Export graphs to Windows Meta File ...................................... 56 Create Project Report ............................................................... 57

Project Management

59

Overview .................................................................................. 59 Project Management................................................................. 59 Create a new Project ...................................................... 59 Open a Project................................................................ 60
Contents iii

User's Guide FLYPS 2.1

Delete a project...............................................................61

Settings

62

Overview...................................................................................62 Set default values......................................................................63 Set Dialog language .......................................................63 Set Frequency.................................................................63 Set Voltage .....................................................................63 Set Units .........................................................................64 Set Head loss calculation method and constants ...........64 Set Life cycle cost calculation default values................64 Set VFD type ..................................................................65 Set program and library paths ........................................65 Create a User Profile ................................................................66

Tutorial

67

Overview...................................................................................67 Basic pump search ....................................................................67 Task description .............................................................67 Solution ..........................................................................68 Pump search based on a pumping system ................................79 Task description .............................................................79 Solution ..........................................................................81

Appendix

88

Description of Flygt pump types ..............................................88 Description of Pump Installation types ....................................90 Description of Toolbar icons....................................................91 Head loss calculation methods .................................................92 Pump search methodology .......................................................94

Glossary

95

iv Contents

User's Guide FLYPS 2.1

FLYPS 2.1 - Introduction

FLYPS 2.1 - A Pump System Design Tool


FLYPS 2.1 is a pump system design tool intended for all professionals in the pump system design and pump application field. The program features pump selection modules and a number of pump system tools such as pipe system design, variable speed analysis, pump performance analysis, flow duration profile and life cycle cost analysis. Outline dimensional drawings and product data sheets can be viewed and printed. The program can be described as a PC-based product catalog designed to support product selection. FLYPS 2.1 is developed by ITT Flygt AB, Market and Sales systems. Design: Magnus Sthl

Flygt US - Manual 2.1, Trumbull, CT 10/1/98

User's Guide FLYPS 2.1

FLYPS 2.1 - Introduction 1

New features in Version 2.1


The following new features have been added, as compared to the previous 1.2 DOS version: Multiple pump search. The pump search can be performed to find solutions with several identical pumps connected in parallel or in series (see "Search" on page 16). Total energy usage. Calculation of total energy usage based on flow duration profile (see Search based on energy consumption on page 24). Life cycle cost (LCC) analysis. Life cycle costs based on equipment cost, energy cost, operating time and interest rate can be calculated (see Life cycle cost analysis on page 38). Performance analysis. Individual and combined pump duty points in multiple pump systems can be calculated (see Duty Analysis on page 35). Pump station design. Support sump dimension,sump volume- and stop level calculations (see Sump Volume Calculation on page 50). Project manager. Project work can be stored in a database (see Project Management on page 59). Dimensional drawings. Link to Acrobat Reader for viewing and printing dimensional drawings in PDFformat (see View Dimensional Drawings on page 30 and Print Outline Dimensional Drawings on page 54) VFD analysis. Analyze one or all pumps when operated as variable speed pumps in pump systems with parallel as well as series pump connection (see VFD - Analysis on page 43.

2 FLYPS 2.1 - Introduction

User's Guide FLYPS 2.1

Getting Started

System Requirements
The minimum software and hardware requirements are: Windows 95, Windows NT, Windows 98, Windows2000 CD-ROM drive, 2x speed Pentium 120 MHz 32 MB RAM 30 MB free disk space for a Client installation, or 30 MB-150 MB for a Laptop installation without CDROM depending on the database contents.

Contents
The CD contains: SETUP.EXE, FLYPS 2.1 installation program FLYPS 2.1, Executable program FLYPS 2.1 Help, Windows help files for Windows95. FLYPS 2.1 Manual, The manual in PDF format Dimensional drawings, All dimensional drawings and the drawing list in a PDF format. ACROBAT, Acrobat Reader from Adobe in several languages.
User's Guide FLYPS 2.1 Getting Started 3

Installation
FLYPS 2.1 must be installed using the installation program SETUP.EXE The program can be installed in three ways. Choose the best suited depending on the environment that the program is intended to be used in.

Standard Installation
Recommended for most computers with a CD-ROM. All program components excluding the dimensional drawings will be installed to the target PC. Note: This installation requires that the CD is inserted in the CD-ROM drive when viewing or printing dimensional drawings.

Minimum Installation (Client)


Recommended for most computers with limited available disk space and working in a network or with a CD-ROM. This installation type will require 16MB of disk space on the target PC and leave the main program product database and the drawing libraries accessible on the CD-ROM. Note: This installation requires that the CD is inserted in the CD-ROM drive during every FLYPS 2.1 session.

4 Getting Started

User's Guide FLYPS 2.1

Customized Installation
Recommended for portable or standalone PC. The required program files and drawing libraries can be installed on the target PC. The installation can be customised by selecting which components you want to install. The components are marked by clicking the check boxes. Unselected components will be left on the CD-ROM and the program will try to find them there. FLYPS Application (the program). FLYPS Product Database, Product databases that the program uses Read-Only. Dimensional drawings, Dimensional drawings in Acrobat PDF format. The installation requires 16-100 MB of free disk space.

User's Guide FLYPS 2.1

Getting Started 5

Installing FLYPS 2.1


1. Start Windows. 2. Insert the FLYPS 2.1 CD in the CD-ROM drive. 3. In the Start menu choose Run. 4. Type D:\Setup and click OK (this example assumes that the CD-ROM drive is named D:). 5. Follow the instructions in the program.

Installation

A Program Group and a number of Program Icons are created during installation: FLYPS 2.1. Main program, starts FLYPS 2.1 Help FLYPS 2.1. Starts Windows Help and opens FLYPS 2.1 Help file UnInstall FLYPS 2.1. FLYPS 2.1 can be uninstalled under the Add/Remove Programs in the Control Panel.

Installing Acrobat Reader


A freeware PDF-file viewer, Acrobat Reader from Adobe, is included on the CD and can be installed together with FLYPS 2.1. Acrobat Reader is used to view and print product dimensional drawings.

6 Getting Started

User's Guide FLYPS 2.1

During installation, the set-up program searches for Acrobat Reader. If the set-up program cant find it or if it is incorrectly installed, you will be asked if you want to install it now. Acrobat Reader is required to utilize all functionality in FLYPS 2.1. Acrobat Reader is available in many languages. If you want to install Acrobat Reader in another language, the installation program is located on the FLYPS 2.1 CD-ROM: If you install a new language to a new location on the disk, you will have to change the command line for Acrobat Reader in the FLYPS Setup.

Network usage
FLYPS 2.1 can run as a multi-user application with a common product database on a network . However, each user needs to make some preparations. 1. Network operator: Copy the contents of the CD to a suitable location on the network server. 2. Each user: Start the Set-up program on the server and choose Client Installation. A limited selection of files is copied to the local PC. Paths and working directory are set to the network server.

User's Guide FLYPS 2.1

Getting Started 7

General Instructions

Start FLYPS 2.1


FLYPS 2.1 is started by clicking the icon created at the installation. Note! FLYPS 2.1 should be started by clicking the icon.

8 General Instructions

User's Guide FLYPS 2.1

Component Description
FLYPS 2.1 is a Windows application consisting of a number of windows, a menu and a toolbar. FLYPS 2.1 has a Multiple Document Interface(MDI) which implies that several windows can be open in one frame. This enables the user to simultaneously work with several tasks or cases in different windows.

Main window
Main window Case-Manager toolbar

Menu

Toolbar

Main window

The user can search or browse products in the Main window. The user can simultaneously work with several tasks or alternative solutions to one task (Cases). The open windows are managed (arranged, minimized etc.) in a standardized way under the Windows item in the menu. The windows can be arranged as Layered, Cascaded or Tiled.

User's Guide FLYPS 2.1

General Instructions 9

Menu
All pump system tools and printouts can be accessed from the Menu. The menu is activated by clicking on it or by pressing ALT + the underlined letter in the menu item name.

Toolbar
Frequently used menu items are also accessible in the Toolbar. The toolbar location and layout is flexible and can be customized by pointing at the toolbar and clicking the right mouse button. The toolbar can be located at the top, left, right, bottom or as a floating window. (See also Description of Toolbar icons on page 91 )
Design Pipe system Flow duration Performance analysis LCC- analysis VFD analysis Product data Dimensional drawings Pump station design

Project Information Setup Create report Save Open existing project Create new project

Case-Manager Toolbar
A new Case can be opened and already opened cases can be accessed by using the Case Manager Toolbar. Up to 15 different cases can be open at the same time.

10 General Instructions

User's Guide FLYPS 2.1

Workflow
All pump system engineering tools in FLYPS 2.1, including product data presentation, system analysis and data printouts become activated when a product is selected. There are two alternative methods to select products In FLYPS 2.1: Browse. The user selects a product in the database by successive choices (see Browse on page 15). Search. The program assembles a collection of pumps that best fulfills the specified requirement (see "Search" on page 16). When a product is selected (highlighted), product data such as Performance curves and Dimensional drawings can be viewed and printed. System analysis such as Performance analysis and Economy analysis are also based on a selected pump, and user input such as pipe system characteristics is required. System characteristics can be defined by a system curve (two points) or by specifying a pipe system. All work corresponding to a project, such as specified pipe systems, flow duration and pump stations can be stored as a project in a project database (see Project Management on page 59).

User's Guide FLYPS 2.1

General Instructions 11

Help
To help the user fully understand and utilize all features in the program, and guide the user through the workflow, FLYPS 2.1 provides an extensive help facility. FLYPS Help uses Windows95-Help and includes descriptions of how to proceed using the program features together with a Tutorial and a Glossary list. Help is accessed in all dialog windows by clicking the Help button. Information about the topic and how to proceed is presented. Links to other related topics are displayed in green text and are accessible by a mouse click. Help is accessible from the Help menu on the Main screen. The help contents with links to all topics are presented.

FLYPS 2.1 Help contents

Tips & Explanations


FLYPS 2.1 provides a facility to display Tips. 1. Point at the desired object with the mouse cursor and click the right mouse button. A Windows-Help window with information related to the desired object appears.

12 General Instructions

User's Guide FLYPS 2.1

Internet shortcuts
FLYPS 2.1 has built-in shortcuts to Flygt's Internet sites. You can easily get the latest news about the program, ask questions at the forum or register as user by using these shortcuts. The FLYPS 2.1 Site contains: News. A home page with latest news about FLYPS 2.1 including patches for updates, etc. Forum. A home page with the possibility of asking questions and exchanging experience about FLYPS 2.1. The questions can be answered by any other FLYPS user or by Flygts local FLYPS coordinator. Registration. A home page to register as a FLYPS user. As a registered user, you will automatically get useful information regarding new program versions and updates. 1. Make sure that a proper command line is set to your Web Browser (See Set program and library paths on page 65). 2. Choose Internet on the Help menu. A drop-down menu appears. 3. Choose the home page that you want to visit.

User's Guide FLYPS 2.1

General Instructions 13

Product Selection

Overview
All pump system engineering tools in FLYPS 2.1, including product data presentation, system analysis and data printouts become activated when a product has been selected. There are two alternative methods to select pumps in FLYPS 2.1: Browse. The user selects a product in the database by successive choices. Search. The program assembles a collection of pumps that best fulfills the specified requirement. See "Workflow" on page 11 for further information.

14 Product Selection

User's Guide FLYPS 2.1

Browse
Browse allows the user to select a product in the database by successive choices based on the product and its configuration. 1. In the Main window, select the Browse Tab. 2. Select in order; Pump type, installation type and product model. A list of all available impellers is displayed. The list can be limited by selecting particular options. 3. Select the preferred impeller(s) by clicking in the pump/impeller list.

Main screen - Browse

User's Guide FLYPS 2.1

Product Selection 15

Search
The program searches for pumps that can meet a specified duty point within a specified interval. The search can be limited to one or several pump types, wet or dry pit installations and a number of other search criteria (see "Set Search Criteria" on page 17) A feature in version 2.1 is the ability to search for solutions with multiple pumps. The program searches for a solution with one or several identical pumps running either in parallel or in series that meet the required duty point. The results from the search are presented in a list showing the most desirable pump choices based on the selected sorting criteria. The list presents general product data together with duty conditions at the duty point. A description of the list contents is found in: Pump list - description on page 25. For further information regarding the search see Appendix "Pump search methodology" on page 94

Main Screen - Search

16 Product Selection

User's Guide FLYPS 2.1

Set Search Criteria


The search interval and the available product range, etc. can be limited by setting specific search criteria: 1. In the Main window, select the Search Tab. 2. Click the Criteria button 3. Select a suitable tab and enter the preferred criteria.

Selection Criteria dialog window

The search criteria includes: General Search interval (in percentage of requested duty point). Minimum and maximum number of pumps for multiple pump searches. Max number of pump hits, based on active sorting criteria, to be presented in the result list. Approval (Standard or FM approved product) Electrical Number of poles in the induction motor (all, one or several). Number of phases (all, 1 or 3). Material Material (all, one or several)

User's Guide FLYPS 2.1

Product Selection 17

Note! When material or number of poles is unspecified, selecting every available option will slow down the search. Select the option All Material and All Poles instead.

Search based on required flow and head


1. In the Main window, select the Search Tab. 2. Enter the required flow, total head and (if known) the static head. This specifies the System curve. If the static head is unknown, set it to zero. 3. Select pump type(s) by clicking on the impeller pictures. (Right click the mouse for a detailed explanation) 4. Select a Single, multiple Parallel- or multiple Series connection. 5. Select a Wet or Dry Pit installation. 6. Select suitable search criteria (see "Set Search Criteria" on page 17) 7. Start the search by clicking the Start search button. A box showing the current search criteria is displayed during the search. The pump alternatives meeting the requirements are presented in a list. The list can be sorted according to different criteria by clicking the proper header. A description of the pump/impeller list contents is found in the Pump list - description on page 25. 8. Highlight the desired pump(s) for product data presentation or pump system analysis by clicking on the products in the pump list.

Search based on required flow and a specified pipe system


If a pipe system is defined, the total required head including losses can be calculated and is used to search for pump selections. The losses in the station piping will be taken into consideration when searching for parallel pumps.

18 Product Selection

User's Guide FLYPS 2.1

1. In the Main window, select the Search Tab. 2. Design the pipe system (see Pipe system design on page 32). 3. Select the option Use calculated head based on system. 4. Enter the required flow and the static head if known. The total head is calculated based on the specified system. 5. Follow the instructions in steps 2 - 7 in section "Search based on required flow and head" on page 18.

Search based on alternative pipe systems


Several different pipe systems can be specified to find different pump solutions to the same task. The different pipe systems are referred to as Cases. 1. Follow the instructions in section Search based on required flow and a specified pipe system on page 18 to specify the first pipe system and search for suitable pumps. 2. Click the # icon in the Case Manager Toolbar. A new Main window with a second case is opened. This case will be a copy of the active case. 3. Repeat the procedure to specify a second pipe system and search for suitable pumps. The search criteria are common for all cases and do not have to be specified again. Up to 15 different systems can be specified. 4. Repeat steps 2 - 3 to specify several alternative systems. Swap between open windows by using the Case Manager Toolbar. The open window can be arranged as Layered, Cascaded or Tiled in the Windows menu.

User's Guide FLYPS 2.1

Product Selection 19

Search based on slurry calculation


This function selects pumps for slurry applications. It calculates the reduction factors caused by the presence of solids for the head and flow from the pump. Note! For homogeneous, viscous or non-settling slurries this function is not an adequate tool. Also, this slurry function only supports the Colebrook-White method for the calculation of friction losses. Only a small amount of input data from the considered application is required to use this tool. The basic input data are the slurry description, particle size distributions (d50 and d85), SGs of the liquid, solids and mixture, solids concentration by weight and volume, mass fraction of particles < 75m and particle shape (sand or mica). These inputs are used to calculate the intersection between the system and pump curves, both in terms of slurry, to give the new duty point. 1. On the main Flyps screen, select Search Tab. 2. From the Tool menu choose Define liquid/slurry or click the icon.

Specify liquid

20 Product Selection

User's Guide FLYPS 2.1

3. Select a slurry type from stored projects. Four slurries are stored as standards; copper and iron ores, mill scale and sand.

Browse liquid

4. You can define your own slurry by entering a description, particle size distributions (d50 and d85), SGs of the liquid, solids and mixture, solids concentration by weight and volume, mass fraction of particles < 75m and particle shape (sand or mica). See Specify liquid overview 5. Click OK twice to return to Search. 6. In the Tool menu choose File and select Save or click the icon. It is very important to save your new slurry to be able to find it later under Browse. 7. Enter the flow and head for the specific project, select connection, installation, pump type and start search. (Note: If you define the piping system as well, the slurry must be defined first.) 8. Mark one or several pumps.

User's Guide FLYPS 2.1

Product Selection 21

Main Screen - Search

9. In the Tool menu, choose Duty analysis or click the icon.

Duty Analysis

The following information can be viewed: Slurry performance curve Shaft power curve for slurry and clean water
22 Product Selection User's Guide FLYPS 2.1

Hydraulic efficiency for slurry and clean water NPSHre System curve Clean water performance curve For more detailed information concerning duty analysis, please look into the respective chapter (seeDuty Analysis on page 35). Explanations of the input parameters in the slurry calculation Description = Slurry name or description. d50=The sieve size opening for which 50% of the particles are finer, [mm]. d85 = The sieve size opening for which 85% of the particles are finer, [mm]. SG Liquid = Specific gravity of the liquid (water is 1). SG Solids = Specific gravity of the Solids. The density of the solids divided by the density of water. SG Mixture = Specific gravity of the mixture. Conc. by weight = Solid concentration by weight, [%]. Conc. by volume = Solid concentration by volume, [%]. Mass fraction (part. < 75m) = The fraction of the mass of solids of particle size smaller than 75 m. This is valid up to 0.5. Above this, the slurry will be considered homogeneous, viscous or non-settling. Particle shape = Sand for spherical shapes or mica for flat shapes

User's Guide FLYPS 2.1

Product Selection 23

Search based on energy consumption


This function is used when the lowest total energy consumption is the primary search criteria for a pumping solution. Most flow duration diagrams can be simplified and reduced to a format of max., average and min. values with very accurate results. This flow data is very useful when searching for a pump selection yielding the lowest energy consumption. It can be used to determine the optimum parallel pump solution. The energy consumption is based on a On-Off pumping system. 1. In the Main window, select the Search Tab. 2. In the Tool menu choose Flow duration or click the icon. A window for specifying the flow duration data appears. 3. Enter maximum(peak)-, average- and minimum flow values and enter the duration in percentage for each flow respectively. Click OK. The Flow duration window is closed.

Flow Duration Diagram dialog box

In the Main window: 1. Select the Use flow duration option.

24 Product Selection

User's Guide FLYPS 2.1

2. Select the Parallel connection. Minimum and maximum number of pumps allowed in the search can be set in the Search criteria (see "Set Search Criteria" on page 17). 3. Select a Wet Pit or a Dry Pit installation. 4. Select suitable search criteria (see "Set Search Criteria" on page 17). 5. Start the search by clicking the Start search button. The pump alternatives meeting the requirements are presented in the pump/impeller list. 6. Sort the pump list by Total energy by clicking the corresponding header. The total energy consumption displayed is based on the entered flow duration data. 7. Mark the desired pump(s) for further product data presentation or analysis by clicking in the pump list.

Pump list - description


The solutions that meet the Search criteria requirements are presented in the pump list. The list contains general product data and duty conditions for each alternative. The list can be sorted according to different criteria; Number of pumps, Divergence from duty point, Specific energy and Total energy consumption. Click on the corresponding header to sort. No of* Number of parallel or series pumps required to meet the requested duty point (if a multiple pumps search has been performed) Flygt product code. Curve code Divergence between the requested and the actual duty point Pump motor input power for the actual duty point. Specific energy at the actual duty point (kwh / million gallons) in US units. Total energy consumption over a period of
Product Selection 25

Product Curve Diff.* Pwr. cons. Spec. energy* Total

User's Guide FLYPS 2.1

energy* NPSHre Flow Rtd. Power Poles Phases Vanes Throughlet Imp. Diam. Drive unit Version

time, based on a specified flow duration NPSH required at the actual duty point Flow at the actual duty point The motor's rated power in kW or HP Number of poles in the induction motor Number of phases of the electrical power supply Number of impeller vanes or blades Impeller throughlet size Impeller diameter or propeller blade angle Drive unit designation Flygt version codes such as: .180, 181, 182Cast Iron pump .090, 091FM approved pump .170, 171, 172Grinder pump .980PH pump .280, 281Stainless Steel pump .410, 490Low head propeller pumps

Install Material

Available pump installation methods (variants) Pump material

* The pump list can be sorted according to these criteria.

26 Product Selection

User's Guide FLYPS 2.1

Product Data Presentation

Display Product data


Product data and performance curves for one selected pump can be presented on the screen. Product data includes a data overview and performance curves. 1. Select a pump either by browsing or searching (see Browse on page 15 or "Search" on page 16) 2. Double click the desired pump in the pump/impeller list or mark it and choose Product data in the Tool menu or click the icon in the toolbar. A window with product data and curves appears.

Product Data - Overview

User's Guide FLYPS 2.1

Product Data Presentation 27

Clicking the Print button in the Overview tab generates a Performance Curve and Rating data printout.

Product data - Rating

Clicking the Print button in the Rating tab generates a Performance Curve and Rating data printout. If the current voltage setting does not correspond to the default voltage in the database, a message like the following is displayed before the Product data windows appears.

Product data information message

28 Product Data Presentation

User's Guide FLYPS 2.1

Display pump curve and duty points


Duty points on the performance curve can be displayed by entering flow or head. 1. Display product data for a selected pump according to the instructions above. 2. Select the Curves tab. 3. Enter a desired flow or head or click the spin controls. Data for the duty points are displayed. The help lines indicate the location of the duty points.

Product data - Curves

User's Guide FLYPS 2.1

Product Data Presentation 29

View Dimensional Drawings


The outline Dimensional drawing for a selected pump can be viewed on the screen. The drawings are stored in PDF-format. 1. Select pumps (See Browse on page 15 or "Search" on page 16) 2. Mark one or several pumps in the pump list and choose Dimensional drawings in the Tool menu or click the icon in the toolbar. A window with a list of the available outline dimensional drawings for each marked pump appears (Many pumps are often available with different discharge connections in different sizes). 3. Double click on a drawing or highlight the drawing and click the View button. The outline dimensional drawing will be displayed on the screen.

Dimensional drawings dialog box

30 Product Data Presentation

User's Guide FLYPS 2.1

Acrobat Reader

User's Guide FLYPS 2.1

Product Data Presentation 31

Pump System Analysis

Overview
FLYPS 2.1 provides a number of facilities to analyze a pump system. These tools are accessed from the Toolbar or the Menu and can only be activated when a pump has been selected. The system curve characteristics must be defined before an analysis can be performed. The system curve can be defined by two specified duty points or by specifying a pipe system. To fully utilize these tools, good pumping knowledge is essential.

Pipe system design


The system curve is the base for all analysis in FLYPS 2.1. A pipe system with two individual pipes (suction piping and/or station piping) per pump and up to three common pipes (force mains) with different dimensions and properties can be specified. A number of user-selectable point losses can be added to each pipe section. Branched systems cannot be analyzed. 1. In the Tool menu, choose Pipe system design or icon in the toolbar. A window for pipe click the system design appears. 2. Select any of the tabs Station Piping 1, Station Piping 2 or ForceMain1 - ForceMain3.

32 Pump System Analysis

User's Guide FLYPS 2.1

3. Enter pipe section length and select Material, Pressure class and Dimension. Values for inside diameters for standard pipes are stored in a table. It is also possible to specify a custom or special pipe by clicking the check box for Standard pipes and entering the inside diameter. 4. Click the spin controls to enter number of pipe fittings for each pipe section. 5. Repeat steps 2 - 4 until the entire system has been defined.

Pipe System Design dialog box

Head loss calculations


Head Loss calculations can be made to determine the required total discharge head (TDH.). FLYPS 2.1 supports two methods of head loss calculations; the Colebrook-White and HazenWilliams equations. Typical values used in these calculations such as roughness / C-factors for different materials and point loss factors can be edited in Setup (See also Set Head loss calculation method and constants on page 64). Single or parallel multi-pump systems can be analyzed. The calculations are based on clean water pumping.
Pump System Analysis 33

User's Guide FLYPS 2.1

1. Design the pipe system (see Pipe system design on page 32). 2. Enter the design flow and the static head.

Head loss calculations

The following is calculated and presented: Total friction loss Total head, (static head and total losses) Liquid velocity for each pipe section (station piping only if the Single (pump) radio button is selected) If the Multi (multiple pump) radio button is selected, different values for the total losses are presented (the flow rate in the station piping will vary depending upon the number of pumps required to meet the total flow). The different values for total head can be used when searching for multiple pump solutions when the number of requested pumps is unspecified.

34 Pump System Analysis

User's Guide FLYPS 2.1

Duty Analysis
Performance analysis is used to study pump performance curves and duty conditions in a single or a multiple pump system. One or several flow/head-, power-, efficiency- and NPSH curves can be displayed for comparing pump alternatives. Duty conditions, combined and for each individual pump, can be studied in a system with several identical pumps. The duty point is based on the system curve. The data is presented in both diagram and table format. The graphs presenting performance curves and duty conditions can be printed or exported to a WMF-file (Windows Meta File) 1. Specify a system by entering a flow, total head and static head or by designing a pipe system and giving a flow. 2. Select pumps by searching or browsing (See Browse on page 15 or "Search" on page 16) 3. Mark one or several pumps in the pump list and choose Duty analysis in the Tool menu or click the icon in the toolbar. A window for performance analysis appears. The marked pumps are transferred into the analysis window. The window is divided into two tabs; Performance curves and Duty conditions.

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Performance curves

Duty Analysis - Performance curves

Mark the desired pump(s) in the list and use the check boxes to select the desired curves. The curve plot can be printed by clicking the Print button. It can also be exported to a WMFfile by clicking the Export button. The following information can be viewed: Performance curve(s). If a pipe system is specified and parallel pumps are used, the reduced pump performance curve will also be displayed. Input power curve(s) Shaft power curve(s) Pump efficiency curve(s) Overall efficiency curve(s) NPSH required curve(s)

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Duty conditions

Duty Analysis - Duty conditions

Mark the desired pump and use the spin controls to enter number of pumps running in the system. The graph can be printed by clicking the Print button. The graph can also be exported to a WMF-file by clicking the Export button. The following information is presented: Each pump: The pump curve for each individual pump. Flow, head, input power, shaft power, efficiency, pump efficiency and specific energy at the duty point for each individual pump when the number of pumps entered is running. Help lines highlight the duty point.

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All pumps The combined performance curve for the selected number of pumps. If a pipe system is specified, this curve will be reduced by the head loss in each pump's station piping. Total values for flow, head (reduced by the station piping), input power, shaft power, overall efficiency, pump efficiency and specific energy for the system with all specified pumps running. Help lines highlight the duty point.

Life cycle cost analysis


The following is an excerpt from the Guide to Life Cycle Cost Analysis for Pumping Systems developed by the Hydraulic Institute and EUROPUMP. Pumping systems account for nearly 20% of the worlds electrical energy demand and range from 25-50 % of the energy usage in certain industrial plant operations. Pumping systems are widespread; they provide domestic services, commercial and agricultural services, infrastructure services, and industrial services for food processing, chemical, petrochemical, pharmaceutical, and mechanical industries. Although pumps are offered to markets as individual machines, they provide a service only when operating as part of a system. The energy and materials consumed in accomplishing this task depend on the design of the pump, the design of the installation, and the way the system is operated. These factors are interdependent. Whats more, they must be carefully matched to each other, and remain so throughout their working lives to ensure the lowest energy consumption and cost. The initial purchase price is a small part of the LCC for high usage pumps. Operating requirements may sometimes override energy cost considerations, but an optimum solution is still possible. A greater understanding of all the components that make up the total cost of ownership will provide an opportunity to dramatically reduce energy, operational, and maintenance cost. Excessive waste and energy usage are important factors

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in global environmental pollution. Reducing energy and material usage also benefits the user by reducing costs. Life Cycle Cost (LCC) analysis is a management tool that can help companies minimize waste and maximize energy efficiency for many types of systems, including pumping systems Life cycle cost analysis is used when comparing life cycle costs for different pumping solutions. Future energy costs and miscellaneous annual costs are calculated into a capitalized present day value based on the selected interest rate. The calculation is based on the summation of the cost elements that make up the LCC. LCC = (Cic + Cin + Ce + Co + Cm + Cs + Cd + Cenv) C = cost element ic = initial cost, purchase price (pump, system, pipe, auxiliary services) in = installation and commissioning cost (including training) e = energy costs (predicted cost for system operation, including pump driver, controls, and any auxiliary services) o = operation cost (labor cost of normal system supervision) m = maintenance and repair cost (routine and predicted repairs) s = down time cost (loss of production) d = decommissioning/disposal cost (including restoration of the local environment and disposal of auxiliary services). env = environmental cost (contamination from pumped liquid and auxiliary equipment) Pumping solutions selected in all open Cases can be compared 1. Select pumps by searching (See Search on page 16) 2. Mark one or several pumps in the pump list and choose life cycle cost in the Tool menu or click the icon in the toolbar. A window for economy analysis

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appears. The marked pumps are transferred into the analysis window. 3. Enter values for interest rate, energy rate, economic project life and annual operation time. 4. To include pumps selected in all open Cases, select the option Include all open cases. All marked pumps in the inactive Cases are imported for the purpose of performing a life cycle cost analysis. 5. Select the LCC button.

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1. Select the Initial Investment and Decommissioning Cost tab. 2. Enter the cost of the pumps, controls, accessories, piping and engineering and design in the appropriate text boxes. This will encompass Cic Total Equipment Cost. The pump cost should be per pump while the balance of the items should be total cost. Costs that are not applicable should be left as 0.00. 3. Continue with installation cost and commissioning cost (including any training), to make up Cin. 4. Enter any decommissioning cost. 5. Select the Annual Costs tab.

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1. The annual pump energy cost is calculated and displayed in a grayed out text box. 2. Enter any other annual energy cost for the auxiliary equipment. This will be added to, and displayed as the Total Energy Cost. 3. The next two text boxes are for the pump operating cost and any additional operating costs. 4. They give the Total Cost of Operation.

5. The next two boxes are for the pump maintenance cost and any other maintenance costs. 6. These two boxes are added together and displayed as Total Cost of Maintenance. 7. Next are inputs for down time cost and environmental cost. These are added to the three above totals to give the Total Annual Cost. 8. Select OK to view the bar graphs in the LCC Window.

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VFD - Analysis
The VFD analysis tool is used to examine the effects of variable speed pumping with a Variable Frequency Drive (VFD). Two ways of applying VFD controls can be analyzed: One-Pump, One pump is speed regulated and all others run at full speed with On-Off control. All-Pumps, All pumps in the system are speed regulated in parallel. A number of graphs can be displayed to show the effects of VFD use in the specified system. Graphs can be printed or exported to a WMF-file (Windows Meta File) 1. Select pumps by browsing or searching (See Browse on page 15 or "Search" on page 16). 2. Mark one or several pumps in the pump list and choose VFD analysis in the Tool menu or click the icon in the toolbar. A window for VFD analysis appears. The marked pumps are transferred into the analysis window. 3. Click on the pump list to select a pump. 4. Select the type of VFD control: One-pump VFD control or All-pumps VFD control. The two VFD control scenarios that are available are by far the most popular. The first, One-Pump VFD refers to a control scenario where one pump is speed regulated while all other pumps that are running are at full speed. This scheme starts with the speedregulated pump coming on first and increasing in speed until it reaches full speed. At this time another pump would be started and this pump would run at full speed while the second would be speed regulated. This would continue until all pumps were running at full speed. The shut down sequence would be in reverse. The second scenario, AllPumps VFD, refers to a control system in which all pumps are speed regulated together. In such a system all pumps would be run at the same time and the same speed. They would be increased in speed until they all reach full speed.
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5. Click the appropriate tab to display a diagram. 6. The graph shown can be printed by clicking the Print button. The graph can also be exported to a WMF-file by clicking the Export button.

VFD Analysis - Frequency curves

Graphs showing the effects of VFD use in the specified system are presented under five different tabs. A description of the diagrams and the presented data follows.

Pump Performance

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VFD Analysis - Pump Performance

The Number of pumps in operation and the operational frequency can be changed by clicking the spin controls. The following data are presented: Blue curves: Combined performance for the specified number of pumps operating and for frequencies in 5 Hz increments. Gray curves: Combined performance for other possible numbers of pumps operating and for frequencies in 5 Hz increments. Red curves: 1. Total performance for the specified frequency and the specified number of pumps in operation. 2. Pump performance for each VFD pump. Black curve: Performance for the const. speed pump(s) (only when using a one-pump VFD control). Help lines highlighting the duty points at the specified frequency - total, regulated and const. speed pumps. Tabulated performance data for a specified frequency and a specified number of pumps in operation.

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Pump Perf. vs. Freq. (Performance versus Frequency)

VFD Analysis - Performance vs. Frequency

The Number of pumps in operation can be changed by clicking the spin controls. The graph shows data plotted versus frequency. Flow - Total, regulated or const. speed pump Head - Total, regulated or const. speed pump The three radio buttons in the pump region Total, Regulated and Constant Speed Pump, are described below. Selecting the Total button will illustrate the values for all pumps combined whether they are a regulated pump or constant speed pump. Selecting the Regulated button will illustrate the values for a single regulated pump, whether OnePump VFD or All-Pump VFD is selected. Selecting the Constant Speed Pump button will display the values for one pump running at full speed, the change in frequency refers to the regulated pump, since the constant speed pump does not change speed.

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Power vs. Freq. (Power versus Frequency)

VFD Analysis - Power vs .frequency

The graphs shows power data plotted versus frequency. Total input power (electrical) Input power (electrical) Shaft power Total efficiency Overall efficiency Pump efficiency VFD efficiency - VFD effects, only available when a Regulated pump is selected.

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Power vs. Flow (Power versus Flow)

VFD Analysis - Power vs. Flow

The graphs shows data plotted versus flow. Total input power (electrical) Input power (electrical) Shaft power Total efficiency Overall efficiency Pump efficiency

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Specific Energy

VFD Analysis - Specific Energy

Specific energy is defined as the energy consumed by a pumping system (pumps and piping system) for a given volume of pumped liquid. This is a measure of the system's energy consumption per unit liquid, and is usually expressed in kWh/Mg (kilowatt hours/million gallons). Specific energy is useful when comparing different pump and piping system solutions from the operating cost point of view. The graphs show data plotted versus flow. One-pump VFD control, Specific Energy when one pump is VFD controlled and the others run at full speed On-Off controlled. All-pumps VFD control, Specific Energy when all pumps in the system are operated on VFD's. On-Off control, Specific Energy when all pumps run at full speed in an On-Off controlled mode.

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Pump Station Design

Sump Volume Calculation


FLYPS 2.1 provides a module for pump station design. The minimum active sump volume and stop levels are calculated to determine the minimum station dimensions. The calculations handle duplex pump stations with one pump in operation and one spare pump. The sump volume calculation is based on pump capacity and the maximum number of starts per hour. The stop level and station dimensions are calculated together with the sump geometry and the specified start level. 1. Select pumps either by browsing or by searching (see Browse on page 15 or "Search" on page 16) 2. Mark one desired pump in the pump list and choose Pump Station design in the Tool menu or click the icon in the toolbar. A window to design a pump station appears. 3. Enter pump design flow. If the pump is selected by searching, the pump flow is transferred and cannot be changed. 4. Select Station type. 5. Select Discharge flange size. 6. Enter grade elevation, use the spin controls to enter Start level and Number of start per hour. The minimum active sump volume, stop level and level for station footings are calculated.

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Pump station design - Minimum sump volume calculation

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Printouts

Print Pump Performance Curve


A pump performance curve for a selected pump can be printed. The printed document includes product data and diagrams with curves including; head, input and shaft power, efficiency and NPSH-required. The printout is handled through the Windows Print manager. The printer settings can be altered by choosing Printer Setup in the File menu. 1. Select pumps (see Browse on page 15 or "Search" on page 16) 2. Double click the desired pump in the pump list. A window with product data and curves appears. You can also mark the desired pump and choose Product data in the Tool menu or click the icon in the toolbar. 3. Select the Overview tab and click the Print button.

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Performance curve printout

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Print Outline Dimensional Drawings


An outline dimensional drawing for a selected product can be printed by using Acrobat Reader. The drawings are stored in PDF-format. The printout is handled by Acrobat Reader through the Windows Print manager. 1. Select pumps (see Browse on page 15 or "Search" on page 16) 2. Mark one or several desired pumps in the pump list and choose Dimensional drawings in the Tool menu or click the icon in the toolbar. A window with a list of all available dimensional drawings for each marked pump appears. 3. Double click on the desired drawing or mark the drawing and click the Print button. Acrobat Reader starts and a window to select options for the printout appears. 4. Select options and click OK.

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Outline Dimensional drawing

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Print Rating data


Rating data for a selected pump can be printed on paper. The printed document includes rated data based on the selected voltage. The printout is handled through the Windows Print manager. The printer settings can be altered by choosing Printer Setup in the File menu. 1. Select pumps (see Browse on page 15 or "Search" on page 16) 2. Double click the desired pump in the pump/impeller list . A window with product data and curves appears. You can also mark the desired pump and choose Product data in the Tool menu or click the icon in the toolbar. 3. Select the Rating tab and click the Print button.

Print System Analysis Reports


A report of a performed system analysis can be printed. All printouts have a uniform layout and include project information, user name and date. The printouts are handled through the Windows Print manager. The printer settings can be altered by choosing Printer Setup in the File menu. 1. Follow the instructions for the preferred analysis. 2. Click the Print button. If a project has not been specified a window to enter project information appears. If required, enter project name and click OK. A printout based on the present values is generated.

Export graphs to Windows Meta File


FLYPS 2.1 provides graphs from Duty analysis and VFDanalysis that can be exported to a Windows Meta File (.WMF).

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Graphs stored as WMF-files can easily be inserted as pictures in other documents such as Word documents. 1. Follow the instructions for the preferred analysis. 2. Click the Export button. A standard dialog window to enter a filename appears. 3. Enter a path and a filename and click OK.

Create Project Report


A composite report consisting of several printouts can be generated. The report can be customized and consists of: Pump Performance Curve, Rating data, Outline dimensional drawings, Sump volume calculations, Pipe system design, Life cycle cost analysis, Duty analysis and a VFD analysis. 1. Select pumps either by browsing or by searching (see Browse on page 15 or "Search" on page 16) 2. Mark one or several desired pumps in the pump list and choose Print in the File menu or click the icon in the toolbar. A window to specify report contents appears. 3. Select items to be included in the report and click OK. If a project has not been specified, a window to enter the project information will appear. Enter the project name and click OK. Windows to select further options for each printout will appear one after the other. 4. Select options when applicable and click Print in each window.

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Create Project Report Dialog box

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Project Management

Overview
Project work, including several Cases, can be stored in a project database. The following data is stored: Project information, such as project name, end user, etc. Entered pipe system(s) Entered flow duration diagram Designed pump station

Project Management
Create a new Project
1. Input data as applicable: pipe systems, flow duration etc. 2. In the Tool menu, choose Project Information or click the icon. A window to enter project information appears. 3. Enter project name, end user and remarks and click OK. 4. In the File menu choose Save. The active case in the project is stored. Choose Save All to save all open Cases.

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Project Information Dialog box

Open a Project
1. In the File menu, choose Open. A window with all previously saved projects appears. The saved projects can be sorted by clicking on the appropriate heading. It is possible to display projects created by all users or only projects created by the current user. 2. Mark the desired project. 3. Click OK. The selected project opens.

Open Project Dialog box

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Delete a project
1. In the File menu choose Open. A window with all previously stored projects appears. The sorting can be changed by clicking the proper heading. 2. Mark the project to be deleted. 3. Click Delete. The marked project is deleted.

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Settings

Overview
Settings are user defined parameters that can be used to customize the program according to the users wishes. All settings are saved to a file with some of the search criteria when closing the program and are restored at the next session. The settings include; dialog language, frequency, voltage, units, head loss calculation constants, economy calculation defaults and also paths to your Internet browser, Acrobat Reader and the outline dimensional drawing libraries. Note that the database contents vary in different countries, therefore changing language, frequency, and voltage might therefore not be applicable to you. A combination of settings can be saved as a User profile. This enables all custom settings to be changed in one operation (See Create a User Profile on page 66).

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Set default values

Setup dialog window

Set Dialog language


1. In the Setup menu choose Language. All available dialog languages appear. 2. Select language.

Set Frequency
Changing frequency is only applicable if the pump database contains both 50Hz and 60Hz products. 1. In the Setup menu choose Setup or click the icon. A window to change settings appears. 2. Select the General tab. 3. Select preferred frequency and click OK.

Set Voltage
Changing voltage is only applicable if the database contains data for several voltages. Note that product and performance data for some pumps is only available in the default voltage.

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1. In the Setup menu choose Setup or click the icon. A window to change settings appears. 2. Select the General tab. 3. Select preferred voltage and click OK.

Set Units
Input and output data can be entered and displayed in different units in any combination. 1. In the Setup menu choose Setup or click the icon. A window to change settings appears. 2. Select the Units tab. 3. Select preferred units and click OK.

Set Head loss calculation method and constants


The Head loss calculation method and constants used in loss calculations, such as roughness, C-factors and point loss factors, can be set according to user wishes. 1. In the Setup menu choose Setup or click the icon. A window to change settings appears. 2. Select the Head loss tab. 3. Select the preferred head loss calculation method, enter the new constants and click OK.

Set Life cycle cost calculation default values


Default values used in the Life cycle cost calculations, such as energy cost and interest rate, can be set according to user preference. 1. In the Setup menu choose Setup or click the icon. A window to change settings appears. 2. Select the Economy tab. 3. Enter proper default values and click OK.

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Set VFD type


Type of VFD properties used in the VFD analysis can be set according to the users preferences. 1. In the Setup menu choose Setup or click the icon. A window to change settings appears. 2. Select the VFD tab. 3. Select the proper VFD type and click OK. The following refers to the three types of VFDs. Flyps will use this value to determine the efficiency of the VFD and in turn calculate the specific energy. The Ideal button selects a typical PWM VFD, but it ignores the effect the VFD can have on a motor related to torque. This effect is taken into account in the next two types. The Frequency ~ Voltage option is the most common PWM VFD type. Here, the voltage remains proportional to the frequency throughout the reduced frequency range. This means the torque capability of the motor remains constant as frequency is reduced, but the attached (centrifugal) load will be reduced more quickly than the linear reduction in frequency. Thus the relative load on the motor becomes less and less as frequency is reduced, and at lower loads the motor will tend to operate less efficiently. The Frequency ~ Voltage2 is the recommended PWM VFD type for centrifugal loads. In this case, as frequency is reduced the voltage is reduced by the square of the reduction in frequency. The motor torque is reduced more quickly than in the above case, roughly in the same proportion as the attached centrifugal load. Thus, the relative load on the motor is almost constant so it operates at about the same high efficiency at lower loads as it did at full load.

Set program and library paths


To be able to utilize the functions in FLYPS 2.1 using Acrobat Reader to view outline dimensional drawings or the Internet shortcuts, proper paths need to be set. If Acrobat Reader and the outline dimensional drawings were installed together with FLYPS2.1, the paths to the viewer and to the drawing library were set during that procedure.
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1. In the Setup menu choose Setup or click the icon. A window to change settings appears. 2. Select the Program tab. 3. Set paths for Acrobat Reader, the outline dimensional drawing library and your Web Browser. Click OK.

Create a User Profile


A combination of settings can be saved with a User profile. User profiles enable all the settings including language, units and calculation defaults etc. to be changed in one operation. 1. In the Setup menu, choose User profile. A window to select, add and edit User profiles appears. 2. Click the Add button. A window to enter settings for a new profile appears. 3. Select the preferred settings and click OK. 4. Enter a name for the new User profile and click OK. 5. Click OK to set the new profile as current and close the window.

User Profile Dialog box

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Tutorial

Overview
We will explore, step by step, the procedures needed to perform your first pump search and basic system analysis in this section. This guided tour is divided into two parts. The first part is basic and covers a pump search together with a simple system analysis and product data printout. The second part is more advanced and covers different aspects of pump searching together with an extensive system analysis. It is assumed that you are comfortable with working in the Windows environment.

Basic pump search


Task description
Find a suitable pump for a duplex wastewater pump station. The pump should be in a wet pit installation. The design flow for the station is 350 GPM and total head is 29 ft. Available voltage is 460 V with a frequency of 60 Hz. The following parameters should be included in the specification of the pump: Product data Product code Curve code
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Voltage [V] Rated power [HP] Rated current [A] Starting current [A] Weight [lbs] Available discharge connection sizes Height of pump [ft] Performance Flow [GPM] Head [ft] Deviation from duty point [%] Input power [kW] Overall efficiency [%] Pump efficiency [%] NPSH required [ft] Enclose printouts of a dimensional drawing and performance curve for the specification after retrieving all the data. If you have studied the manual for FLYPS 2.1, try to solve this task by yourself. Otherwise, let the following pages guide you through the pump selection process, and learn how to retrieve performance and product data and how to print outline dimensional drawings and performance curves.

Solution
Pump search The first step in a search is to enter the duty point. Enter flow and head. Static head can be set to zero if it is unknown. The entered value in the input box is total head, i.e. the sum of static head and friction loss. The C-type impeller is typical for wastewater applications (See Appendix Description of Flygt pump types on page 88 for more information). It has a high efficiency and excellent solids handling properties. We are searching for a wet pit pump installation, so be sure that the installation type is set to wet.
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The specification stated that one pump should be able to handle the duty point. This means that the connection should be set to single. Remember to always make sure that proper search criteria are used. Incorrect search criteria may result in an incorrect pump selection. A search interval of 10 % is adequate for low flows. For larger flows, use a narrower interval. The min. / max. value in the multiple pump search section is not accounted for when running a search with a single connection. FM approval is not normally needed for standard wastewater applications. For the rest of the parameters, use the default values. Search for all poles, phases and materials. 1. Select the Search tab 2. Specify duty point. Enter flow. 250 GPM. Static head is unknown. Enter 0 ft. Enter head. 29 ft. 3. Click to choose impeller type C.

4. Set Connection to single. 5. Set Installation to wet-CP. 6. Click the Search criteria button. A window to set Search criteria appears Set Search interval. - 10% and + 10%. Set Approval to Standard. Make sure that All poles, All phases and All materials are selected. Click OK.

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1. Click the Start search button to perform a search. After running the pump search, the pump list is displayed. It should look like the one below. Minor differences may be noted due to different product mixes in a later version of the program.

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Main screen - Pump list

The pump list can be sorted according to different criteria. Sorting can be done with respect to no of pumps, deviation from duty point, specific energy and total energy. The fact that we are searching for a single pump means that it is useless to sort by number of pumps. A duration diagram has to be specified in order to sort on total energy. The relevant parameters left to sort on are deviation from duty point and specific energy. The following performance data can be obtained in the result list: Duty point flow Power consumption (input power) NPSH req. The C 3102 is the least expensive one in the pump list. Lets analyze this pump to determine if the duty point is acceptable. Specifically, we want to determine if the duty point is within the preferred operational range on the pump curve, if NPSH req. is acceptable, if the efficiency is sufficient, etc.

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Duty analysis 1. Select the C 3102 LT 63-441 by clicking on it in the result list. Several pumps can be selected for the analysis; click on all desired pumps in the list 2. In the Tool menu choose Duty analysis or click the icon in the toolbar. A window for duty analysis appears. 3. Click the check boxes for Shaft power and Pump efficiency to select those curves.

Performance curves for the C 3102-LT 63-441

This duty point is acceptable. Now, when the pump is selected it is time to fill in the data and performance tables. All performance data can be found in the Duty analysis window. Some of the data can also be found directly in the pump list. The following data can be obtained under the Performance curves tab. The values for: Shaft power Pump efficiency. 4. Click on the Duty condition tab.
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Performance at the duty point for a C 3102-LT 63-441

The following data is obtained under the Duty condition tab. Duty point values for: Flow Head Input power Efficiency Specific energy. 5. Click Close to return to the Main window

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We have now found all of the data for the performance table in the specification. Performance Flow [GPM] Head [ft] Difference from duty point [%] Input power [kW] Shaft power [HP] Overall efficiency [%] Pump efficiency [%] Req. NPSH [ft] Product data 1. Choose Product data in the Tool menu or click the icon. It is also possible to double click on the selected pump in the pump list. A window for the Product data presentation appears. Note that the icon will be enabled only when one pump is selected. 2. A window with available installation types appears. Select installation type "P" and Click OK. 253 29.7 0.1 4.2 4.6 34.1 41.6 12.9

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The product data window is divided into three sections; Overview, Rating, and Curves.

Product data overview

Overview - contains general product information such as voltage, frequency, rated power, rated current, throughlet size, etc. Rating - contains information about different ratings; for example ratings for warm liquids. Please note that this information is not available for all products. Curves - Pump performance curves. The following data can be obtained in the Product data window Rated power [HP] Rated current [A] Starting current [A] Weight [lbs] 3. Click Close to return to the Main window.

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Dimensional data Now we have almost all of the information to fill in the product data sheet in the specification. The information about discharge connections and the height of the pump is still missing. These can be obtained by viewing the outline dimensional drawings. 1. In the Tool menu choose Outline Dimensional drawings or click the icon in the toolbar. A window with available installations and discharge connections appears. The specification stated that the pump should be installed in a wet pit. The FLYGT denomination for a permanent submerged installation is P, and the pump denomination is therefore CP. (See Appendix "Description of Pump Installation types" on page 90 for more information)

Outline Dimensional drawings for different installations and different discharge connections for the C 3102-LT 63-441.

The following requested data can be obtained from the drawing: Available discharge connections Available discharge connections for the selected pump are 100/100 and 150/150.

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1. Select CP 3102-LT DN100/DN100 2. Click View or double click on the row with the requested discharge connection to view the dimensional drawing. Acrobat Reader starts and displays the PDF file.

Dimensional drawing CP 3102 LT

The following data can be obtained from the drawing: Height of the pump The drawing can be viewed and zoomed in and out by using the magnifying glass. The dimensional drawings contain outline dimensions of the pump, guide bars and discharge connection size. The dimensional drawing can be printed from within acrobat and from FLYPS 2.1. 3. Click Close to return to the Main window.

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The resulting product data table should look like this: Product data Product code Curve code Rated shaft power [HP] Voltage [V] Rated current [A] Starting current [A] Weight [lb] Available discharge connections Height of pump [in] Performance Flow [GPM] Head [ft] Difference from duty point [%] Input power [kW] Shaft power [HP] Overall efficiency [%] Pump efficiency [%] Req. NPSH [ft]

3102.180 63-441 5.0 460 6.5 31.0 258 4/4 and 6/6 24.3

253 29.7 1 4.2 4.6 34.1 41.6 12.9

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Printout of pump performance curve and outline dimensional drawing. 1. In the File menu choose Print or click the icon to create a report. A window to specify a custom report appears. 2. Click the check boxes for Dimensional drawing and Performance curve in the report dialog box. 3. Click OK to start the Printout.

Report dialog box.

Pump search based on a pumping system


Task description
Select suitable wastewater pumps for the system below. The Number of pumps is unspecified and has to be determined. One of the pumps shall be an installed spare. The system should be designed for minimum energy consumption. Average flow during the day is 1500 GPM with peaks in the morning and evening. The peak flow is 2500 GPM. Minimum flow (night time) is 550 GPM. The flow is at minimum level for 35 % of the day, average flow is 60 % /day and the peaks last for 5 % of the day. The force main and individual station pipes are made of ductile iron, Class 53. All pipes are considered to be new.

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Available voltage is 460 V and the frequency is 60Hz.

Pipe system illustration Sump floor elevation W.L. in sump Outlet elevation W.L. at outlet + 200 ft. + 208 ft. + 230 ft. + 219 ft.

Individual station pipe Length Diameter Material 1 Discharge con. 1 Valve 1 Check valve 2, 90 degree bend. Force main #1 Length Diameter Material 3 x 90 degree bend. 1 x Outlet 5000 ft 20 in Ductile Iron k=0.3 k=1.0 15 ft. 10 " Ductile iron, Class 53 k=0.3 k=0.3 k=0.9 k=0.3

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Solution
Pipe system specification The first step is to calculate the losses in the system. This is done in the Design pipe system window. The pipe system is divided into two different kinds of pipes, station piping and force main pipe. The total flow runs through the force main and the flow in the station piping is the flow from each pump. You can specify one or two station pipes for each pump in the system and up to 3 force mains. Diameter, length, material/ roughness and point losses must be specified for every pipe section. If length is omitted for a pipe section, it will not be accounted for in the loss calculation. Five pipe sections are normally enough to model almost any pipe system, including complex ones. Station piping 1. In the Tool menu, choose Design Pipe System or click the icon in the toolbar. A window for designing a pipe system appears. 2. Enter flow. 2500 GPM 3. Enter static head 15 ft. 4. Select the first station piping tab. 5. Enter length. 15 ft. 6. Make sure Standard pipes are selected. 7. Choose ductile iron in the Material drop down list box. 8. Choose CL 53 in the Pressure class drop down list box. 9. Choose 10 in the Dimension drop down list box. 10.Specify point losses. Add 1 x Discharge connection, 2 x 90 Bend, 1 x Valve and 1 x Check valve by clicking on the spin control in the edit boxes.

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Tutorial 81

Loss calculation. Specification of station piping.

Note. The water velocity stated in the lower left corner is calculated for single pump duty only. When running multiple pumps, the velocity in the station pipes will decrease due to changing duty points. The loss factors can be edited in the setup. Force main 1. Specify losses in the force main. Select the Force main 1 tab or click on the pipe section in the picture of the pipe system. 2. Enter length. . 3. Make sure Standard pipes are selected. 4. Choose ductile iron in the Material drop down list box 5. Choose CL53 in the Pressure class drop down list box 6. Choose 20 in the Dimension drop down list box 7. Specify point losses. Add 3 x 90 Bend and 1 x Outlet by clicking on the spin control in the edit boxes.

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Loss calculation. Specification of force main.

If the option multi pumps is selected, the duty points for a different number of pumps are shown in a list. Both head loss and total head are shown. The min. and max. values for the number of pumps defined in Search criteria determines the number of duty points shown in the list. The loss calculation method used in this case is HazenWilliams. Calculation methods can be changed in the Setup. For more detailed information about the calculation methods see Appendix Head loss calculation methods on page 92. 8. Click OK to return to the Main window. When back at the main window, the edit boxes for static head, total head will be filled in and disabled. Duration diagram specification The flow variation throughout a 24 hour period is, in this case, substantial. This implies that we have to specify a duration diagram in order to do an accurate energy consumption calculation. 1. In the Tool menu choose Duty analysis or click the icon in the toolbar. A window for specifying a duration diagram appears.
User's Guide FLYPS 2.1 Tutorial 83

2. Specify maximum flow (peak flow). Enter Max. flow. 2500 GPM. Enter duration. 5%. 3. Specify average flow. Enter Avg. flow. 1500 GPM. Enter duration. 60%. 4. Specify minimum flow. 550 GPM. Enter duration. 35%

Duration diagram.

Graph plotting a can be switched off by clicking in the Graph checkbox. 5. Click OK to return to the Main window. Pump search based on a given system and with a specified flow duration diagram The basic details of a search were described in Tutorial 1, and will not be discussed here. The C-type impeller is typical for wastewater applications. It has a high efficiency and excellent solids handling properties. In this case, the number of pumps is not specified. 1. Make sure Calculate head based on system is selected. 2. Make sure Use duration diagram is selected. 3. Click to choose impeller type C.

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4. Set Connection to Parallel. 5. Set Installation to Wet. 6. Check search criteria. To have same results as in the tutorial set search interval to -5% and +5%. 7. Click the Start search button to perform a search. A list of pump alternatives fulfilling the requirements will appear. 8. Sort the result list on total energy consumption. Click on the Total energy column heading.

Results from pump search. Sorted with respect to total energy.

The solution with the lowest specific energy at the maximum flow does not necessarily have to be the one with the lowest total energy consumption. In systems with normal flow distribution and high losses, multiple pump solutions tend to have lower total energy than solutions with few pumps. This is due to the fact that the losses decrease when fewer pumps are running.

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Tutorial 85

Duty point analysis Always remember to check if the duty point(s) are on the preferred part of the curve, not power limited, NPSH required is OK, etc. When running with multiple parallel pumps it is important to check all duty points. Normally when selecting a pump, alternatives with negative difference are discarded. 1. Select the best pump (according to total energy) in the result list. Click on the first pump in the result list. 2. In the Tool menu, choose Duty analysis or click the icon in the toolbar. A window for duty analysis appears. 3. Select the Duty condition Tab. 4. Check single pump duty. Decrease No. of pumps running by clicking on the spin control.

Duty analysis one pump running

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Summary The objective in this tutorial was to optimize for minimum energy consumption. By sorting the pump list with respect to specific energy, we will find a single CP 3201 which can handle the specified duty point. How much energy is saved by selecting the optimum 2xCP 3127 solution instead of the single pump solution? Total energy during 1 year for the 2 pump alternative is 61,600 kwh and for the single pump alternative 74,500 kwh. The energy saved by using 2 pumps instead of one is 74,500 - 61,600 = 12,900 kwh. Whether or not these savings are justifiable can be analyzed with the Life cycle cost tool.

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Tutorial 87

Appendix

Description of Flygt pump types


Pump type

B C D F H L M

Description Open multi vane impeller for clear liquids and liquids containing finer solids such as sand, silt, sediment, etc.). Closed single and multi-vane impellers with large throughlets primarily designed for solids bearing liquids of low and medium abrasiveness. Vortex impeller and with large throughlet primarily designed for solids bearing liquids of low and medium abrasiveness. Open screw type cutting impeller for liquids containing solids and fibers. Open single and multi-vane high chrome impellers with abrasion-resistant volute for extra tough applications and very abrasive liquids. Shrouded single or multi-channel mixed flow impellers with bowl type diffuser pump casing. Open multi-vane impellers with integral grinder cutter for liquids containing solids and fibers.

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With volute (NP, NS, NT, NZ) Without volute (NL) State of the art, high efficiency, semi-open, self-cleaning, multi-vane impeller and volute with a patented cleaning/cutting groove. Recommended for pumping all types of liquids ranging from clean water to highly solids bearing liquids, such as raw sewage, sludge, fibrous liquids and liquid manure. Axial flow propeller pumps for high flow, low head pumping of clean or lightly contaminated liquids

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Appendix 89

Description of Pump Installation types


Installation Description

F H J L P S T Z

Semi permanent, free-standing for hose or pipe connection. Semi permanent, quick connection suspended installation with an integral check valve. Semi permanent installation with swiveling guide bar to permit mixing and pumping. Semi permanent installation of pump inside the vertical discharge column. Semi permanent wet pit installation with pump guided by two guide bars with automatic connection to a discharge connection. Portable version with hose coupling or flange for connection to discharge pipeline. Permanent dry pit installation with flange connection to suction and discharge piping (vertical installation). Permanent dry pit installation with flange connection to suction and discharge piping (horizontal installation).

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Description of Toolbar icons


Icon Description Create Report. Opens a window to specify the contents of a project report Setup. Opens a window to change user defined default values. Project Information. Opens a window to enter project information. Pipe system design. Opens a window for pipe system design and head loss calculations Flow duration. Opens a window to specify a flow duration diagram. Duty analysis. Opens a window for curve comparison and duty point analysis. Life cycle cost analysis. Opens a window for Life cycle cost analysis. VFD-analysis. Opens a window for variable speed pumping analysis. Product data. Opens a window with product data for a selected product. Outline dimensional drawings. Opens a window to view and print outline dimensional drawings. Pump station design. Opens a window for pump station design and sump volume calculations.

User's Guide FLYPS 2.1

Appendix 91

Head loss calculation methods


The loss calculations in FLYPS 2.1 are based on the assumption that the pipes are entirely filled with liquid and that the liquid has the qualities of clean water. Density: 62.4 lb/ft Kinematic viscosity: 1.2 x 10-5 ft/s Description of loss calculation: Htot = Htot = Hs Hf = = Hs + Hf Total head Static head Head losses

The head losses consist of two parts: hf= hfl + hpl where hfl = Friction losses, hpl = Point losses In FLYPS the friction losses can be calculated with two different methods: Colebrook-White
L V2 h fl = f D 2g

is dependent upon the Reynolds number (Re) and the roughness of the pipe.
Re = VD

For turbulent flow (Re > 4000), Colebrook-White's formula is:


1 2.5 = 2 log10 + 3.7 D Re f f

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where; f = Darcy-Weisbach friction factor, = absolute roughness-ft, D = inside diameter of pipe-feet, = kinematic, viscosity-ft2/sec. Hazen-Williams
100 h fl = .002083 L C
1.85

gpm 1.85 d 4 .8655

where L = pipe length, including equivalent length for loss thorugh fittings-ft., C = friction factor for Hazen-Williams, gpm = flow of liquid, d = inside diameter of pipe-inches

User's Guide FLYPS 2.1

Appendix 93

Pump search methodology


During a duty point search for a pump, the program searches for the intersection between the system curve, which runs through the requested duty point, and the pump performance curve. This intersection is the duty point for this pump curve. The distance between the requested and actual duty point is calculated and compared with the distance to the requested duty point (see graph below). If this relative distance falls within the given search interval, the curve is regarded as a hit. The search interval is given with both a positive and a negative limit. Performance curves where the requested flow is less than 15% of the curve's maximum flow are not included in the search. This is done so that the program will not suggest pumps where the duty point would be close to the shutoff head.

C1 C2 P1 P2 D1 D2 point

Pump curve System curve Requested duty point Actual duty point (calculated intersection) Distance to requested duty point Distance between requested and actual duty

Relative divergence between actual and requested duty points is calculated as follows: Rel. div. = D2 / D1

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Glossary

Cd Decommissioning/Disposal Cost (Cd) Decommissioning cost includes the restoration of the local environment and the disposal of pumps piping and auxiliary equipment. In the vast majority of cases, the cost of disposing of a pumping system will vary little with different designs. Cenv Environmental Cost, Including Disposal of Parts and Contamination from Pumped Liquid (Cenv) The cost of contaminant disposal during the lifetime of the pumping system varies significantly depending on the nature of the pumped product. Certain choices can significantly reduce the amount of contamination, but usually at an increased investment cost. Examples of environmental contamination can include cooling water and packing box leakage disposal, hazardous pumped product flare-off, used lubricant disposal, contaminated used parts, such as seals. Costs for environmental inspection should also be included. Cs Downtime and Loss of Production Cost (Cs) The cost of unexpected downtime and lost production is a very significant item in the total LCC and can rival the energy costs and replacement parts costs in its impact. The value of lost production can dwarf all other elements. Despite the design or target life of a pump and its components, there will be occasions when an unexpected failure occurs. In those cases
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where the cost of lost production is unacceptably high, a spare pump may be installed in parallel to reduce the risk. If a spare pump is used, the initial cost will be greater but the cost of unscheduled maintenance will include only the cost of the repair. Cm Maintenance and Repair Cost (Cm) Obtaining optimum working life from a pump requires regular and efficient servicing. The manufacturer will advise the user about the frequency and the extent of this routine maintenance. Its cost depends on the time and frequency of service and the cost of materials. The design can influence these costs through the materials of construction and components chosen and the ease of access to the parts to be serviced. Co Operation Cost(Co) Operation costs are labor costs related to the operation of a pumping system. These vary widely depending on the complexity and duty of the system. For example, a hazardous duty pump may require daily checks for hazardous emissions, operational reliability, and performance within accepted parameters. On the other hand, a fully automated nonhazardous system may require very limited supervision. Regular observation of the functioning of a pumping system can alert operators to potential losses in system performance. Performance indicators include changes in vibration, shock pulse signature, temperature, noise, power consumption, flow rates, and pressure. Ce Energy Cost (Ce) Energy consumption is often one of the larger cost elements and may dominate the LCC especially if pumps run more than 2000 hours per year. Energy consumption is calculated first by gathering the data on the pattern of the system output. If output is steady, or essentially so, the calculation is simple. If output varies over time, then a time-based usage pattern needs to be established.

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Cin Installation and Commissioning (Start-up) Cost (Cin) Installation and commissioning costs include the following: Foundations - design, preparation, concrete and reinforcing, etc. Setting and grouting of equipment on foundation Connection of process piping Connection of electrical wiring and instrumentation Connection of auxiliary systems and other utilities Provisions for flushing or 'water runs' Performance evaluation at start-up. Training of users and owners. Cic Initial Investment Cost (Cic) Although the initial investment cost will contain purchase price of pumps, piping and equipment, it can also include the following items: Engineering, e.g. design and drawings, regulatory issues The bid process Purchase order administration Testing and inspection Inventory of spare parts Auxiliary equipment for cooling and sealing water Acrobat reader A program from Adobe used to view outline dimensional drawings and other PDF-files. Acrobat Reader is distributed together with FLYPS 2.1 Browse A product is selected in the database by successive list choices based on user preferences.

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Case An alternative solution to a task. Can, for exaple, be used to study the impact of a different pipe system design. In the program, the cases appear as different sets of the Main window. Navigation between Cases is handled by The Case Manager Toolbar. Export graphs Graphs showing various curves in the Performance analysis and VFD analysis functions can be saved in WMF-format (Windows Meta File). Graphs stored in WMF format can easily be inserted as pictures into other document such as Microsoft Word, Excel and Powerpoint, etc. Force main The portion of the piping system which is common to all pumps. Input power The electrical power used by the motor. Internal losses The frictional and point losses in the station piping in a specified pipe system. This value is used to create the reduced pump curve. Minimum active sump volume The minimum effective volume in the sump between the start and stop level settings, necessary to prevent excessive starts per hour. Motor efficiency The ratio of shaft power to electric input power, expressed in percent (%). Overall efficiency The ratio of the liquid power delivered by the pump to the input power into the motor, expressed in percent.

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Performance curve A printout of a complete pump curve with extensive product data and various curves in a standardized layout. The curves include: head, input and shaft power, efficiency and NPSHrequired. Point loss A concentrated friction or shock loss, created by a pipe fitting, valve, or similar. Present day value The algebraic sum of the disocunted positive and negative future value of goods. Often referred to as present worth. Pump efficiency The ratio of the liquid power delivered by the pump to the pump shaft power, expressed in percent. Pump search methodology The program searches for pumps that fulfill the search criteria, and with a performance curve close to the requested duty point. Radio button Mutually exclusive push button; only one button can be selected at any given time. Rated power The maximum shaft power that an electric motor can sustain for its designated duty conditions, when operated with nameplate voltage and frequency. Search interval Flow interval along the system curve, as a percentage of the duty point. Shaft Power The mechanical output power from an electric motor, usually expressed in HP.

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Specific Energy The energy used to pump a unit volume for a given pump in a given system, often expressed in kilowatt hours per million gallons (kWh/Mg). Spin controls The up and down arrows shown to the right of a field of entry. By clicking the up arrow, the value in the field increases, consequently the down arrow decreases the value. System curve The system characteristics are described by the System curve. The system curve shows the total discharge head (T.D.H.) in the pipe system as a function of the flow. Throughlet size The (clear) open circular, rectangular or elliptical internal passage through the impeller, which indicates the largest diameter solid that may be passed. Total efficiency The ratio of the liquid power delivered by the pump to the input power into the VFD, expressed in percent. This term is only applicable to pumps that are operated through a variable speed drive. Total input power The electrical power into the VFD for the total number of pump selected. This term is only applicable to pumps that are operated through a variable speed drive. User profile A combination of user defined settings stored under a name. Enables the user to change all settings in one operation.

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