220 3DR M11 00001

Design Criteria for Fluid and Slurry Handling
25635-220-3DR-M11-00001-000
.
Source
Code.
TABLE OF CONTENTS
SECTION DESCRIPTION PAGE
1.0. GENERAL ...................................................................................................................... 3

2.0. SOURCE CODES .......................................................................................................... 3
3.0. CODES AND STANDARDS ........................................................................................... 3
4.0. REFERENCE DOCUMENTS ......................................................................................... 4
5.0. GENERAL CONSIDERATIONS ..................................................................................... 5
6.0. FLUID PROPERTIES ..................................................................................................... 5
7.0. GRAVITY SLURRY LAUNDERS ................................................................................... 6
8.0. JUNCTION BOXES, SAMPLING BOXES AND DISTRIBUTORS ............................... 12
9.0. PRESURE PIPELINES ................................................................................................ 18
10.0. PUMPS ........................................................................................................................ 21
ATTACHMENTS
ATTACHMENT 1: Wilson Nomogram for Limit Settling Velocity (ANSI/HI 12.1-12.6, 2005)
ATTACHMENT 2: Modified Durand’s Limiting Settling Velocity Parameter Diagram (Warman,

2009)
ATTACHMENT 3: Effect of average particle size and impeller diameter on Hr and Rh (ANSI/HI
12.1/12.6, 2005)
ATTACHMENT 4: Application of froth factor to pump selection (ANSI/HI 12.1/12.6, 2005)
Electronic documents, once printed, are uncontrolled and may become outdated.
Refer to the electronic documents in Project InfoWorks stobambas for current revision.
BECHTEL Confidential © BECHTEL 2010. All rights reserved
Page 2 of 28
25635-220-3DR-M11-00001-000
.
Source
Code.
1.0. GENERAL
These criteria will govern the design of In-Plant Fluid and Slurry Handling for Las
Bambas Project for Xstrata Tintaya S.A. These criteria will be applied in conjunction
with site conditions and mechanical specifications governing specific elements of
individual projects.
2.0. SOURCE CODES
The source code letters listed for each criterion refer to the origin of that criterion value.
In certain cases, two source codes may be referenced. The following letter code
designators are used:
Code Description
A Criteria provided by the client
B Standard industry practice
C Bechtel recommendation
D Vendor originated criteria
E Criterion from calculations
F Engineering handbook data
G Assumed data
H Criteria provided by “Technology Supplier”.
3.0. CODES AND STANDARDS
3.1. Codes and Standards
Unless specifically stated otherwise, the design of all mechanical systems will be
B
based on the current standards and/or codes that concern to the specific system as
issued by the following organizations:
ANSI/HI American National Standards Institute / Hydraulic Institute

API American Petroleum Institute
ASME American Society of Mechanical Engineers
AWWA American Water Works Association.
In addition to the applicable codes and standards, the design will comply with all laws
or regulations of local authorities. In the event of conflicting requirements between
codes and standards, the most stringent will apply.
Page 3 of 28
25635-220-3DR-M11-00001-000
.
Source
Code.
4.0. REFERENCE DOCUMENTS
This Design Criteria shall apply in conjunction with the Project Documents, Drawings
C
and Bechtel Standard Documents listed below.
4.1. Project Documents
This Hydraulic Design Criteria shall be used in conjunction with the following project
documents:
25635-220-3DR-V01-00001 DESIGN CRITERIA FOR PROCESS
25635-220-3DR-H01-00001 DESIGN CRITERIA FOR ENVIRONMENTAL
25635-220-3DR-M10-00001 DESIGN CRITERIA FOR MECHANICAL DESIGN
25635-220-3DR-M85-00001 DESIGN CRITERIA FOR MATERIAL HANDLING.
4.2. Drawings
• Process Flow Diagrams (PFD’s).

• Process and Instrumentation Diagrams (P & ID’s).
4.3. Bechtel Standard Documents
• “Engineering Design Guide for Fluid Flow in Piping Systems”, Doc. No. 3DG-
M11-00001 – Rev. 003.
• “Engineering Design Guide for Pipeline Orifice Sizing”, Doc. No. 3DG-M47-
00001 – Rev. 001.
• “Mechanical Engineering Design Aid for Materials Handling Seminar 1967
Liquids”, Doc. No. 3DZ-G04H-00002, Rev. 000.
• “Engineering Department Procedure, Design Criteria”, 3DP-G04-00001,
Revision 001.
• “Design Guide for Hydraulics for Slurry Flow”, 3DG-K04-00007, Revision 000.
4.4. Technical References B
• Abulnaga, B.E. (2002). “Slurry Systems Handbook”, McGraw-Hill, 2002.

Available on Knovel (www.knovel.com).
• ANSI/HI (2005). “American National Standard for Rotodynamic (Centrifugal)
Slurry Pumps”, American National Standards Institute, Inc., Hydraulic Institute
Standard, ANSI/HI 12.1-12.6-2005.
• ANSI/HI (1998). “Pump Intake Design”, American National Standards Institute,
Inc., Hydraulic Institute Standard, ANSI/HI 9.8-1998.
• Green, H.R., Lamb D.M., and Taylor, A.D. (1978). “A New Launder Design
Procedure”, Society of Mining Engineers of AIME Annual Meeting, Denver,
Colorado, February 28 to March 2, 1978, Preprint No. 78-B-16 for Presentation
Page 4 of 28
25635-220-3DR-M11-00001-000
.
Source
Code.
at the AIME Annual Meeting.
• Karassik, I.J., Messina, J.P., Cooper, P., and Heald, C.C., Editors (2008).
“”Pump Handbook”, 4th Edition, McGraw-Hill, 2008. Available on Knovel
(www.knovel.com).
• Mayerle, R., Nalluri, C. and Novak, P. (1991). “Sediment transport in rigid bed
conveyances”, IAHR Journal of Hydraulic Research, Vol. 29, 1991, No. 4.
• Mays, L.W. (1999). “Hydraulic Design Handbook”, McGraw-Hill, 1999.
Available on Knovel (www.knovel.com).
• MOP (2001). “Manual de Carreteras”, Dirección de Vialidad, Dirección
General de Obras Públicas, Ministerio de Obras Públicas, República de Chile.
• Nalluri, C. and Kithsiri, M.M.A.U. (1992). “Extended data on sediment
transport in rigid bed rectangular channels”, IAHR Journal of Hydraulic
Research, Vol. 30, 1992, No. 6.
• Warman (2009). “Slurry Pumping Manual”, 5th Edition, Weir Slurry Group,
Warman International Ltd., 2009.
• Wilson, K.C., Addie, G.R., Sellgren, A., and Clift, R. (2006). “Slurry transport
using centrifugal pumps”, 3rd Edition, Springer.
5.0. GENERAL CONSIDERATIONS
Dimensioning of slurry transport system shall consider the flow fluctuation over the C
metallurgical balance, as indicated in the Process Design Criteria and Process Flow
Diagrams. Special consideration shall be given to streams where the maximum
instantaneous flow rates can be significantly higher than the balance value.
Design flow requirements for maintenance conditions (where certain equipment may
be offline due to maintenance) shall be evaluated on a case-by-case basis for each
system.
Minimum flow rates, based on the expected fluctuation below the balance value, shall
also be evaluated.
Froth factors for maximum flow shall be applied as indicated in this document. In
addition, a realistic minimum value of froth factors shall be evaluated on a case-by-
case basis to determine the minimum volumetric flow rate.
6.0. FLUID PROPERTIES
6.1. Water B
Standard charts or tables, such as those in the “Hydraulic Design Handbook (Mays,
1999), shall be used for aqueous systems. Parameters shall be adjusted for design
temperature and plant elevation, where applicable.
The chemical properties of water, in particular reclaim water, shall be evaluated to
determine whether allowances for reduction in pipe internal diameter due to scaling
should be included in calculations.
Page 5 of 28
25635-220-3DR-M11-00001-000
.
Source
Code.
6.2. Slurry Viscosity C
Slurry yield stress is not considered to be significant within in-plant slurry transport
systems due to the high turbulence in these systems, and use of an apparent viscosity
is considered to be sufficient for system design.
Apparent viscosities according to the percent solids by volume of the slurry shall be as
follows (Green et al., 1978).
% Solids by volume Apparent Dynamic Viscosity

[mPa-s]
<10 2
20 3
25 4
30 8
Additional values may be obtained from Green et al. (1978).

Rheology tests shall be conducted for slurries with percent solids by volume is greater
than 30%, or high proportion of solid material finer than 40 microns, and for thickened
tailings and concentrate slurry streams.
7.0. GRAVITY SLURRY LAUNDERS
This section outlines the criteria to be used for design of in-plant slurry transport
gravity flow systems in pipes and open channels.
7.1 General B
Gravity transport systems shall avoid full flow through closed pipelines where feasible,
and especially the formation of siphons.
Calculations shall be carried out according to the method described in “A New
Launder Design Procedure” (Green et. al., 1978).
7.2 Normal Depth of Flow – Darcy-Weisbach Equation
Flow velocity in open channels shall be calculated by using the Darcy-Weisbach

equation and the Colebrook-White equation (or equivalent), with the diameter
conventionally used in these equations replaced by four times the hydraulic radius, as
shown below.
Darcy-Weisbach equation:
8 Rgi B
V =
λ
Page 6 of 28
25635-220-3DR-M11-00001-000
.
Source
Code.
Where:
i = Launder slope [m/m]
λ = Darcy-Weisbach Friction factor [non dimensional]
R = Flow hydraulic radius [m]
= S/P
S = Flow cross-sectional area [m2]
P = Flow wetted perimeter [m]
V = Average velocity in the launder [m/s]
g = Gravitational acceleration [m/s2].
Colebrook-White equation:
1 ⎛ ks 2.51 ⎞
= −2 ⋅ log⎜⎜ + ⎟⎟
λ ⎝ 3.7(4 R) Re⋅ λ ⎠
4 RV
Re =
υ
Where:
ks = Boundary roughness [m]
Re = Reynolds number [non-dimensional]
υ = Slurry kinematic viscosity [m2/s].
Based on previous experience in design of slurry transport systems, the following

values of roughness, ks, shall be used in the Colebrook-White equation:
Material ks [mm]
HDPE 0.15
Smooth Rubber (*) 0.40 C
Steel 0.70
Concrete 1.40
Profiled Rubber (*) 4.00
(*) Including neoprene
Due to effect of high velocity free surface flows typical in slurry launders, the
roughness values given above are higher than those typically used for pipe full flow,
and are consistent with the Manning n values quoted below.
7.3 Normal Depth of Flow – Manning Equation
Generally, use of the Darcy-Weisbach equation with an apparent viscosity is preferred

B
for computation of slurry flows. However, alternatively, Manning’s formula may be
used for calculating the normal depth of flow:
Page 7 of 28
25635-220-3DR-M11-00001-000
.
Source
Code.
1 2 / 3 1/ 2
V = R i
n
Where:
V = Average velocity in the launder [m/s]
n = Manning roughness coefficient
i = Launder slope [m/m]
R = Flow hydraulic radius
= S/P [m]
P = Flow wetted perimeter [m].

values shall be used for the Manning roughness coefficient (n):
Material _n_ C
HDPE 0.010
Rubber - Smooth 0.011
Steel 0.012
Concrete 0.013
Rubber – Profiled 0.015
7.4 Limit Settling Velocity B
In order to avoid solids settling, the limit settling velocity shall be evaluated based on
the method in Green et. al. (1978).
Limit settling velocity is evaluated combining the Darcy-Weisbach and Shields

equations:
8θgd (Ss − 1)
VL =
λ
VL = Limit settling velocity [m/s]

g = Gravitational acceleration [m/s2]
θ = Shields parameter to prevent settling of solid
= 0.8
d = Maximum expected particle size [m]
Ss = Relative density of solid particles
λ = Darcy-Weisbach friction factor [non dimensional].
Alternatively, the Durand-Rayo formula may be used:

VL = 1.25 x FL x [2 x g x R x (Ss-1)] 0.25
Page 8 of 28
25635-220-3DR-M11-00001-000
.
Source
Code.
Where:
VL = Limit Settling Velocity [m/s].
FL = Function of solid particle size and concentration of solids (see
McElvain and Cave Limit Settling Velocity Parameter Diagram,
Attachment 2).
R = Hydraulic radius of launder [m].
Ss = Relative density of the solid particles with respect to the
conveying fluid [non-dimensional].
Launders in Grinding Circuits

Note that in the grinding circuit with coarse particle sizes, use of these relationships
may result in excessively high required velocities, and hence alternative methods
(such as those by Mayerle et. al., 1991 and Nalluri and Kithsiri, 1992) based on bed-
load transport of solids in fixed bed channels may be applied.
7.5 Flow Velocity Restrictions B
In order to avoid solids settling, the minimum flow velocity shall be at least 10% higher
than the limit settling velocity.
To prevent excessive wear the maximum flow velocity shall be limited to 5 m/s where
possible.
7.6 Depth Restrictions
Where feasible, flow depth in open or pipe launders shall be restricted to the following:
h h
h
D B W
h = [ 0.15 - 0.5 ] h > 0.15 h > 0.3
D B W
h = Flow depth
D = Pipe diameter
B = U-shaped launder width
W = Rectangular launder width
Page 9 of 28
25635-220-3DR-M11-00001-000
.
Source
Code.
7.7 Froude Number
The flow depth for design flow range shall be outside the critical flow condition, as
C
determined by Froude number (Fr) = 1.0. Where feasible, Froude numbers less than
1.4 shall be avoided (Abulnaga, 2002). The following formula shall be used to
calculate Froude number:
V
Fr =
gS
T
Where:
V = Flow velocity [m/s]
g = Gravitational acceleration [m/s2]
T = Flow stream surface top width [m].
7.8 Launder Height and Freeboard B
Maximum depth and minimum freeboard (clear height between the top of the launder
sidewall and the surface of the flow stream) calculations shall be performed at the
maximum flow rate including froth.
Where feasible, dimensioning criteria for launder height and freeboard of open
launders shall consider the following:
a) Launder heights shall be at least three times the flow depth.
b) For flow in pipes, diameter shall be at least two times the flow depth.
c) Freeboard shall be at least 0.5 m.
d) In runs with fittings, elbows, bends or restrictions (transfer boxes), freeboard
shall be at least 1.0 times the velocity head (V2/2g).
Should criteria d) result in excessive launder heights (such as on steep concentrate

collection launders) then pipe launders or bolted launder covers can be considered.
However, criteria a), b) and c) should still be met.
7.9 Froth Flow Factors in Launders
Hydraulic conditions in launder shall be computed based the slurry flow without froth,
as described in previously. Where applicable, the depth of flow in the launder shall be
increased using a froth factor, as follows:
hf = FF x h
Where:
hf = Depth including froth
FF = Froth factor
h = Depth based on slurry flow without froth.
Page 10 of 28
25635-220-3DR-M11-00001-000
.
Source
Code.
The following froth factors shall be used for computing the maximum depth of flow for
sizing of launders:
FROTH FACTOR FOR LAUNDERS

CONCENTRATOR PLANT
F.F.
Grinding Cyclone O/F 1.0 B
Rougher Concentrate 2.0
First Cleaner Concentrate 2.0
Scavenger Concentrate 1.2
Second/Third Cleaner Concentrate 1.5
Regrind Discharge 1.0
Regrind Cyclone O/F 1.6
Concentrate Thickener U/F 1.0
Final Tailings 1.0
FROTH FACTOR FOR LAUNDERS

MOLYBDENITE PLANT
F.F.
Rougher Feed 2.0
Rougher Flotation Concentrate 5.0
B
Rougher Flotation Tailings 2.0
First Cleaner Flotation Concentrate 5.0
First Cleaner Flotation Tailings 2.0
Second Cleaner Column Cells Concentrate 5.0
Second Cleaner Column Cells Tailings 2.0
Scavenger Flotation Concentrate 5.0
Scavenger Flotation Tailings 2.0
Second Cleaner Flotation Concentrate 5.0
Second Cleaner Flotation Tailings 2.0
No froth factor shall be applied for determining minimum flow.
7.10 Minimum slope in concentrate Launders
In addition to the above criteria, for bulk, cooper, and molybdenum launders minimum
slopes must be 4%, depending particulary on process considerations for each case.
Page 11 of 28
25635-220-3DR-M11-00001-000
.
Source
Code.
8.0. JUNCTION BOXES, SAMPLING BOXES AND DISTRIBUTORS
8.1. General B
Junction boxes shall be used at changes of direction and for joining flows. A junction
box that collects either the process stream for sampling or the sample reject will be
called a sampling box.
A distributor will be used where it is necessary to divide a slurry stream into two or
more streams of specified proportions having approximately the same solids
concentration, size distribution and composition as the original stream.
Junction boxes shall be designed so that the entering stream will fall on a body of
slurry based on the free fall stream trajectory and not on the bottom or walls of the
box. The volume shall be sufficient to absorb and dissipate the excessive kinetic
energy whilst avoiding solids deposition and or particle separation.
8.2. Overflow Weir Outlets
Design slurry levels in chambers upstream of free discharge overflow weirs shall be
determined assuming critical conditions at the weir, allowing for end contractions at
the sides of the outlet (Mays, 1999):
Q = 0.385 2 g ⋅ (L − 0.2 ⋅ H c ) ⋅ H c
3/ 2
The design slurry level upstream of the outlet is computed as follows, allowing for high
turbulence in slurry boxes:
Hd = 1.1 Hc Typical turbulence in slurry boxes

Hd = 1.2 Hc High turbulence, for example in drop pipes.
Where:
Q = Flow [m3/s]
L = Width of rectangular outlet [m]
Hc = Critical energy head above outlet/weir invert [m]
Hd = Design slurry level above outlet/weir invert [m].
Where required for design optimization, sharp- or broad-crested weir equations can be
used based on weir geometry.
Page 12 of 28
25635-220-3DR-M11-00001-000
.
Source
Code.
8.3. Outlets to Launders F
Design slurry levels in chambers upstream of circular or rectangular lateral outlets into
open channel or pipe launders shall be determined using culvert inlet-control design
charts or equations, such as those given in the Manual de Carreteras (MOP, 2001). A
turbulence design factor shall be included in determining the design slurry level.
Hd = 1.1 He Typical turbulence in slurry boxes

Hd = 1.2 He High turbulence, for example in drop pipes.
Where:
He = Headwater above outlet invert, from culvert design chart or equation [m]
Hd = Design slurry level above invert of outlet [m].
8.4. Orifice Head Losses
The head loss across submerged orifices, such as dart valves, rectangular underflow
baffles, or bottom outlets shall be estimated according to the following formula:
2
⎛ Q ⎞ 1
ΔH = ⎜⎜ ⎟⎟
⎝ Cd ⋅ S ⎠ 2g
Where:
ΔH = Loss of head through orifice [m]
Q = Flow [m3/s]
S = Orifice cross-section area [m2]
Cd = Coefficient of discharge, for sharp edged orifices C = 0.61
For dart valves orifice, flow velocity shall be less than 2.5 m/s. This value shall be
reviewed case by case in terms of the wear, lead loss and the particular conditions of
each design.
8.5. Dart Valve Travel Height
When fully open, dart valves should be raised above the slurry in the box.
Therefore, hydraulic calculations should estimate the maximum depth of fluid above
a dart valve outlet, to provide input to minimum required travel height for the dart
valve.
Page 13 of 28
25635-220-3DR-M11-00001-000
.
Source
Code.
8.6. Dimensioning of Transfer Boxes B, C
Transfer boxes shall be dimensioned to avoid overflow and splashing. For this
purpose, the following guide shall be followed (Refer to Figure 1).
^2
R > V /2g
Lc>2Lp
h > 0.5 m ≤5B
Lp
>1.2Hd
Hd
B
D≥h
0.5 m/s < V < 1.5m/s
Figure 1
• Hydraulic independence between the incoming and outgoing flows of the

transfer box shall be maintained. It is recommended that a vertical clearance
between the levels defined by the design depth at nominal (balance) flow of
the discharge section and the invert of the incoming launder be 0.5 meters
minimum.
• The width of the transfer box must be at least 2.0 times the width of the feeding
or discharge section of the box. The nearest sidewall shall be 400 mm from the
edge of the inlet channel.
• The length of the transfer box Lc must be equal to or more than 2 times the
horizontal distance Lp of the path described by the calculated drop parabola
upper nape (trajectory) of the slurry feeding to the liquid surface into the box at
nominal (balance) flow.
• Velocity through the underflow baffle shall be greater than 0.5 m/s to avoid
settlement of solids, and less than 1.5 m/s to limit turbulence downstream.
Page 14 of 28
25635-220-3DR-M11-00001-000
.
Source
Code.
• EITHER the vertical clearance of the outlet must be at least 20% more than the
design depth, Hd, defined for maximum flow, OR a vent pipe shall be located
no further than 5 diameters and no less than 2 diameters from the outlet and
the discharge shall be designed so that the flow reaches free surface flow
before venting. Vent pipe diameter shall be at least a quarter of the diameter of
the discharge, with a minimum of 6”. The choice between both alternatives
shall be made considering such factors as costs and/or space availability for
the box.
• The discharge section shall be arranged for a smooth transition downstream to
normal flow depth.
• Where feasible, transfer boxes shall be designed with a bed or buffering
cushion, bottom drainage (quick opening and full flow) and covers to prevent
overflowing. For boxes below ground level, the bottom of the box shall be
sloped to a pit in one corner so that the box can be easily pumped out.
• Layout of slurry outlets shall consider a transition piece with a flat bottom or a
transition area with a variable section, to provide an excess discharge area to
absorb flow turbulences and fluctuations. The use of expansion nozzles shall
be considered in the design of some inlets to the transfer boxes in order to
reduce drop speed.
8.7. Pump Boxes B, C
Pump boxes shall be sized and arranged to avoid overflow, splashes, and sharp
variations in static pressure of slurry at the pump inlet.
Pump boxes shall be sized for not less than 60 seconds retention time at design flow
rates. Retention time will be based on the volume of the sump between the minimum
level above the top of the pump suction nozzle and the lip of the sump overflow weir.
For froth slurries, the flow rate used to size the pump box volume shall be increased
by the froth factor in Section 8.9.
Slurry level with respect to pump inlet level shall be adequate to avoid pump
cavitations at maximum flow rate, (need to exceed NPSHr and minimum submergence
for pump).
The recommended minimum submergence S of the outlet fitting below the free
surface of the liquid, given the outlet diameter D, may be obtained from the
relationship, according with ANSI/HI9.8:
S/D=1.0+2.3FD
Where:
S = minimum submergence of the outlet fitting below the free surface of the liquid [m]
D = Outlet fitting internal diameter [m]
V
FD = Froude number =
gD
Page 15 of 28
25635-220-3DR-M11-00001-000
.
Source
Code.
V = Outlet fitting velocity [m/s]

Pipe Centerline
Freeboard shall be not less than 300 mm above the top of the overflow. The overflow
shall be at least one pipe size larger than the pump suction outlet or main flow inlet
pipe.
Concrete pump box outlet nozzles shall include a sacrificial flanged wear spool piece
as required for abrasive service, and the inclusion of such a spool for lined steel pump
boxes will be dependent on the service conditions.
8.8. Sampler Boxes
The slurry levels inside vendor provided sampler boxes shall be checked against
the depth and flow of the incoming launder to ensure acceptable hydraulic
conditions at the inlet to the sampler.
8.9. Froth Flow Factor for Transfer and Distribution Boxes
The following flow factors shall be used for computing the maximum flow rate for
design of transfer, distribution and pump boxes:
Q = FF x QS
Where:
Q = Flow rate including froth
FF = Froth factor
QS = Slurry flow rate.
Page 16 of 28
25635-220-3DR-M11-00001-000
.
Source
Code.
FROTH FACTOR FOR SLURRY BOXES

CONCENTRATOR PLANT
FF
Rougher Feed 1.0
Regrind Feed 1.2
1st clean feed 1.2
2nd clean feed 1.2
Concentrate thickener 1.2
Tailings thickener 1.0
FROTH FACTOR FOR SLURRY BOXES

MOLYBDENITE PLANT
FF
Rougher Feed 1.5
Regrind Feed 2.0
1st clean feed 2.0
2nd clean feed 2.0
Concentrate thickener 2.0
Tailings thickener 1.5
When determining minimum flow, froth factor value shall be reviewed in a case by
case basis.
Additional Freeboard for Froth
In addition to the froth factor applied to flow rate as presented above, pump,
distribution and transfer boxes should consider a froth freeboard to allow for froth that
will collect in the box and float on top of the slurry surface. Froth freeboard values
shall be as specified in the Process design criteria.
8.10. Emergency Overflow
Slurry boxes shall be provided with emergency overflows. As a general rule, the
design flow for the emergency overflow shall be based on the following conditions:
For boxes with 1 or 2 outlets Maximum design inflow with all outlets closed.
For boxes with 3 or more outlets Maximum design inflow with at least half the
outlets closed.
Page 17 of 28
25635-220-3DR-M11-00001-000
.
Source
Code.
9.0. PRESSURE PIPELINES
9.1. General
9.1.1 Friction Losses

B
Friction losses shall be calculated by using the Darcy-Weisbach equation and the
Colebrook-White equation (or equivalent).
Darcy-Weisbach equation:
λL V 2
Hf =
D 2⋅g
Where:
Hf = Pipe friction losses [m]
λ = Darcy-Weisbach Friction factor [non-dimensional]
L = Total length of the pipe reach [m]
D = Pipe internal diameter [m]
V = Flow velocity [m/s]
g = Gravity acceleration [m/s2].
Colebrook-White equation:
1 ⎛ k 2.51 ⎞
= −2 ⋅ log⎜⎜ s + ⎟⎟
λ ⎝ 3.7 D Re⋅ λ ⎠
VD
Re =
υ
Where:
Re = Reynolds number [non-dimensional]
υ = Slurry kinematic viscosity [m2/s]
ks = Pipe wall equivalent sand grain roughness [m].
9.1.2 Fitting Losses

B, F
Discrete fittings losses shall be calculated by using the following equation:
V2
HL = K
2⋅ g
Where:
HL = Pipe fittings losses [m].
Page 18 of 28
25635-220-3DR-M11-00001-000
.
Source
Code.
Typical values of K, applicable for Reynolds numbers > 2 x 105, are given below.
Description K
Close radius bends (R/D = 1)
22.5° 0.15
45° 0.3
90° 0.75
Long radius bends (R/D = 2 to 6)
22.5° 0.1
45° 0.2
90° 0.4
Tees (90o equal offtake)
Flow through 0.2
Full flow to branch 1.9
Full flow from branch 1.6
Valve
Full open sluice or gate valve 0.2
Full open globe valve 10.0
Pipe entry and exit

Square entry 0.5
Protruding entry 0.8
Exit 1.0
Typical values of K can be taken from standard references such as “Pump Handbook”
(Karassik et. al., 2008) or “Hydraulic Design Handbook” (Mays, 1999). Fittings losses
for non-standard components should be obtained from suppliers.
It may be necessary to adjust fittings loss coefficients for high viscosity or non-
Newtonian fluids.
9.1.3 Hydraulic Transient (Water Hammer)

C
A preliminary hydraulic transient (water hammer) assessment shall be performed for
each pumped pipeline system. Where indicated by this preliminary assessment, a
detailed hydraulic transient analysis (numerical model) shall be performed.
9.2. Aqueous Fluids Systems
This section summarizes criteria for design of Fresh Water, Potable Water, Seal and
Cooling Water, Process Water and Solution storage and distribution systems.
9.2.1 Type of Flow B
Transport and distribution piping for water and solution systems shall be designed for
full pipe flow.
Page 19 of 28
25635-220-3DR-M11-00001-000
.
Source
Code.
Fresh water, such as water for dust suppression, pump seal water and cooling water
shall be sized according to the flow and the pressure recommended by the equipment
supplier.
9.2.2 Head Losses B, F

Friction losses shall be calculated according to Section 9.1.1.
The following roughness values shall be used for pressurized aqueous lines:
Material ks [mm]
Steel (aged light rust) 0.15

Steel (aged, scaled water systems) 1.0
HDPE 0.06
Field testing is highly recommended for designs involving any existing pipelines.
9.2.3 Flow Velocity Criteria B

Generally water and aqueous solution piping systems shall be sized using the
following velocity criteria:
Type of Service Velocity [m/s]
General service 1.2 – 3.0

Pump suction and drain lines 1.2 – 2.0
The velocity criteria above are intended as a general guideline. Velocities outside the
range specified above may be acceptable and should be evaluated on a case-by-case
basis of friction losses and water hammer.
9.3. In – Plant Slurry Pipelines B
This section outlines the criteria to be used for design of pressurized in-plant slurry
pipelines.
The limit settling velocity shall be determined in accordance with the Wilson
nomogram given in the ANSI/HI slurry pump standard (see Attachment 1).
Alternatively, the limit settling velocity may be calculated according to the Durand-
Rayo formula:
VL = 1.25 x FL x [2 x g x D x (Ss-1)] 0.25
Where:
VL = Limit Settling Velocity [m/s].

FL = Function of solid particle size and concentration of solids (see
McElvain and Cave Limit Settling Velocity Parameter Diagram,
Attachment 2).
Page 20 of 28
25635-220-3DR-M11-00001-000
.
Source
Code.
D = Inside diameter of pipeline [m].
Ss = Relative density of the solid particles with respect to the
conveying fluid [non-dimensional].
9.3.1 Flow Velocity B

Flow velocity shall exceed by at least 10 % the limit settling velocity under all
operating conditions.
In order to prevent excessive wear in the pipe, the maximum flow velocity shall not
exceed 5 m/s.
9.3.2 Head Losses B

Slurries are transported in a pseudo-homogenous turbulent regime and friction losses
calculated according to Section 9.1.1 allowing for the viscosity of the slurry.
roughness values shall be used for pressurized slurry pipelines:
Material ks [mm]
C
Steel 0.15
Steel with abrasive slurries 0.05
HDPE 0.06
Rubber 0.2
Field testing is highly recommended for designs involving any existing pipelines.
Losses for fittings (bends, tees, valves etc.) shall be included in the head loss
calculations.
Pumping head calculations shall be conducted for both maximum and minimum static
head scenarios.
Methodology for calculating head losses shall be limited to slurry pipelines not
exceeding 500m in length.
10.0. PUMPS
10.1. General
10.1.1 Operation points

B
Pump operating ranges shall be defined according to minimum, nominal (balance) and
maximum/design flow rates as defined by the process flow diagrams and process
design criteria.
System curves shall be computed for minimum and maximum static heads, and pump
selection be appropriate for the full range of expected operating conditions.
The nominal (balance) operating point shall be as close to but just to the left of BEP.
The maximum/design operating point may be to the right of BEP. However, the flow
Page 21 of 28
25635-220-3DR-M11-00001-000
.
Source
Code.
rate at the maximum/design operating point shall be at least 10% below the maximum
flow on the supplier’s pump curve, to avoid operating beyond the pump curve.
Special attention shall be paid to filter feed pumps, that the above criteria be applied to
initial conditions that have low back pressure and high flow rates, to avoid pump run-
out under this condition.
B
10.1.2 Pump speed
Slurry pumps shall be selected at a maximum operating speed at least 10 percent
below the recommended maximum by the pump supplier.
10.1.3 Motor selection

B
Motor nameplate power rating selection shall be for non-overloading conditions; and
shall be, as a minimum, the calculated power at maximum operating condition
increased by 10%, or the next greater motor size, whichever is greater.
Motor power required shall allow for a transmission loss of 6% for gear reducers and
10% for V-belt drives, but shall be confirmed by pump supplier.
10.2. Slurry Pumps
10.2.1 Slurry derating factors

B
Appropriate head and efficiency derating factors for performance and motor selection
of centrifugal pumps handling slurry shall be specified by the pump supplier. Where
pump supplier data is not available, typical charts given in ANSI/HI 12.1-12.6-2005
shall be used (see Attachement 3).
• The head derating factor shall only be used for selection of the pump speed
and/or impeller size.
• The efficiency derating factor shall only be used for selection of the motor size.
10.2.2 Froth factors

Pump selection shall be sized taking into account the following froth factors:
Q = FF x QS
Where:
Q = Flow rate including froth
FF = Froth factor
QS = Slurry flow rate.
Page 22 of 28
25635-220-3DR-M11-00001-000
.
Source
Code.
FROTH FACTOR FOR PUMPS
FF
Concentrator Plant
Regrind pumps 1.1
Vertical mill recirculation 1.1
Column cells feed 1.1
Molybdenite Plant
Final concentrate 1.5
Column cells feed 1.2
Rougher tailings 1.1
Pump sizing shall be completed in accordance with vendor recommendations, with

motor and final drive selection chosen to ensure that pump run out or motor tripping at
full speed when operating on slurry does not occur, when the system does not include
variable frequency drive. Selection should also be cognizant of relatively flat pump and
pipeline system curves which become difficult to control of excessive froth safety
factor are used.
Attachment 4 shows the application of froth factor to preliminary pump selection.
Sumps should be designed to allow for de-aeration of frothy pulps, froth spray water
provided and sufficient surface area to ensure acceptable flux rates are achieved.
Note: consideration must be given to the reduction of Froth Factors at pump suction
due to residence time and related agitation of the slurry in the tank. Pump selection
will not be proper when high Froth Factor is used without allowing for such reduction.
10.2.3 Pump impeller tip speed B

The maximum impeller tip speed for rubber-lined impellers shall be 23 m/s. The
maximum impeller tip speed for hard metal impeller shall be 28 m/s. Higher peripheral
speeds may be considered in specific cases.
B
10.2.4 Net Positive Suction Head
Net Positive Suction Head available (NPSHa) in meters of slurry shall be calculated
according to the following formula:
NPSHa = Hatm-Hvap + Zs –Hi

Sm
Page 23 of 28
25635-220-3DR-M11-00001-000
.
Source
Code.
Where:
Hatm = Absolute atmospheric (barometric) pressure at the liquid supply level, in
meters of water.
Hvap = Absolute vapor pressure of liquid at pumping temperature, in meters of
water.
Zs = Static pressure developed by height of slurry above (+) or below (-) the
centerline of the pump suction inlet, in meters of slurry.
Hi = Suction line losses including entrance loss, friction loss and pressure
drop across valves, in meters of slurry.
Sm = Slurry Specific Gravity [t/m3]
NPSHa values computed using the above formula shall be compared directly with
NPSH required (NPSHr) values given on curves provided by the pump supplier
developed from water tests, without adjusting for specific gravity. The pump supplier
shall be consulted when pumping highly viscous slurries, or slurries with entrained air,
since NPSHr values can be greater.
NPSHa shall be at least 1m greater than the NPSH required (NPSHr) by the pump as
indicated by the pump Supplier, at 40 % sump level minimum.
10.2.5 Pump material B

Hard metal impellers and liners shall be used for slurry pumps handling very coarse
solids and tramp metal. All other pumps shall be lined with rubber or neoprene lining.
10.2.6 Seals B
Where feasible, slurry pumps shall have gland shaft seals flushed with pressurized
seal water. For slurry pumps in remote locations (such as booster pump stations)
without adequate supply of gland seal water, mechanical seals may be considered.
Milk of lime pumps shall have mechanical seals if possible; otherwise minimum water
flow gland seals may be utilized.
Page 24 of 28
25635-220-3DR-M11-00001-000
.
Source
Code.
ATTACHMENT 1: Wilson Nomogram for Limit Settling Velocity (ANSI/HI 12.1-12.6, 2005)
Page 25 of 28
25635-220-3DR-M11-00001-000
.
Source
Code.
ATTACHMENT 2: Modified Durand’s Limiting Settling Velocity Parameter Diagram
(Warman, 2009)
Page 26 of 28
25635-220-3DR-M11-00001-000
.
Source
Code.
ATTACHMENT 3: Effect of average particle size and impeller diameter on Hr and Rh

(ANSI/HI 12.1/12.6, 2005)
This chart is valid for solids concentration volume, Cv = 15%, with solids Ss=2.65 and a
negligible amount of fine particles. Impeller diameters are given in mm and inches.
Efficiency reduction factor Rη=Rh.
For different solids concentration volume and Ss or slurries with fine particles, head reduction
factor shall be multiplied concurrently by the correction factors Cs, Cfp and Ccv.
0.65
⎛ ( Ss − 1) ⎞
Cs = ⎜ ⎟
⎝ 1.65 ⎠
Cfp = (1 − fractional content of particles by weigh < 75μm )
2
⎛ Cv ⎞
Ccv = ⎜ ⎟
⎝ 15% ⎠
Page 27 of 28
25635-220-3DR-M11-00001-000
.
Source
Code.
ATTACHMENT 4: Application of froth factor to pump selection (ANSI/HI 12.1/12.6, 2005)
Page 28 of 28

220 3DR M11 00001

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

220 3DR M11 00001

Uploaded by

Copyright:

Available Formats

Design Criteria for Fluid and Slurry Handling

SECTION DESCRIPTION PAGE

1.0. GENERAL ...................................................................................................................... 3

ATTACHMENT 2: Modified Durand’s Limiting Settling Velocity Parameter Diagram (Warman,

ATTACHMENT 4: Application of froth factor to pump selection (ANSI/HI 12.1/12.6, 2005)

2.0. SOURCE CODES

3.0. CODES AND STANDARDS

3.1. Codes and Standards

ANSI/HI American National Standards Institute / Hydraulic Institute

4.1. Project Documents

• Process Flow Diagrams (PFD’s).

4.3. Bechtel Standard Documents

4.4. Technical References B

• Abulnaga, B.E. (2002). “Slurry Systems Handbook”, McGraw-Hill, 2002.

5.0. GENERAL CONSIDERATIONS

6.0. FLUID PROPERTIES

% Solids by volume Apparent Dynamic Viscosity

Additional values may be obtained from Green et al. (1978).

7.0. GRAVITY SLURRY LAUNDERS

7.2 Normal Depth of Flow – Darcy-Weisbach Equation

Flow velocity in open channels shall be calculated by using the Darcy-Weisbach

Based on previous experience in design of slurry transport systems, the following

(*) Including neoprene

7.3 Normal Depth of Flow – Manning Equation

Generally, use of the Darcy-Weisbach equation with an apparent viscosity is preferred

Based on previous experience in design of slurry transport systems, the following

7.4 Limit Settling Velocity B

Limit settling velocity is evaluated combining the Darcy-Weisbach and Shields

VL = Limit settling velocity [m/s]

Alternatively, the Durand-Rayo formula may be used:

Launders in Grinding Circuits

7.5 Flow Velocity Restrictions B

7.6 Depth Restrictions

7.8 Launder Height and Freeboard B

Should criteria d) result in excessive launder heights (such as on steep concentrate

7.9 Froth Flow Factors in Launders

FROTH FACTOR FOR LAUNDERS

FROTH FACTOR FOR LAUNDERS

No froth factor shall be applied for determining minimum flow.

7.10 Minimum slope in concentrate Launders

8.2. Overflow Weir Outlets

Hd = 1.1 Hc Typical turbulence in slurry boxes

Hd = 1.1 He Typical turbulence in slurry boxes

8.4. Orifice Head Losses

8.5. Dart Valve Travel Height

h > 0.5 m ≤5B

0.5 m/s < V < 1.5m/s

• Hydraulic independence between the incoming and outgoing flows of the

8.7. Pump Boxes B, C

V = Outlet fitting velocity [m/s]

8.8. Sampler Boxes

8.9. Froth Flow Factor for Transfer and Distribution Boxes

FROTH FACTOR FOR SLURRY BOXES

FROTH FACTOR FOR SLURRY BOXES

Additional Freeboard for Froth

8.10. Emergency Overflow

9.1.1 Friction Losses

9.1.2 Fitting Losses

Pipe entry and exit

9.1.3 Hydraulic Transient (Water Hammer)

9.2. Aqueous Fluids Systems

9.2.2 Head Losses B, F

Steel (aged light rust) 0.15