PUMP DESIGN

Step 1: Nozzles design

Liquid Inlet and Outlet
The Harker equation (1978), modified for SI unit, for the optimum pipe (and nozzle) diameter:
W0.45
Dopt = 8.41 ρ0.31

Where W in kg/hr and ρ in kg/m3

W = Mass Flow Rate = 1486.73 kg/hr
ρ = 941.81 kg/m3
W0.45 1486.73 0.45
Dopt = 8.41 = 8.41 = 26.94 mm = 1.06 in
ρ0.31 941.810.31

Based on Schedule 40 pipe dimension, the pipe size to be chosen is 1.25 in nominal size.

For nominal size of 1.25 in, internal diameter is 1.38 in or 0.04 m

Therefore area of pipeline (based on internal diameter):
πD2 π(0.04)2
A= = = 0.001 m2
4 4
Step 2: Velocity of Liquid
Based on area of the pipeline, the velocity of the liquid flow:
Q = Av
Q 0.00044
Rearrange, v = A = = 0.45 m/s
0.001

Step 3: Friction in pipe

In calculating the friction in pipe, the whole length of the pipe is taken into account which is
the summation of length in suction side and discharge side. Friction in pipe is determined based
on the following equation:
8fL v 2
hf =
D 2g
In determining the value of friction factor, f, the value is taken based on Moody diagram as in
below with known Reynolds number, Re and relative roughness, Ɛ/D;
Reynolds Number is determined based on the following equation;
ρvD (941.81)(0.45)(0.04)
Re = = = 50456.58
μ 0.000297

Taking the type of the pipe used as commercial steel pipe, the roughness, Ɛ is 0.046 mm.
Thus the relative roughness is
Ɛ/D = (0.046) / (0.04 x 1000) = 0.0013
Therefore based on the Moody diagram, the friction factor is 0.02
Thus the friction loss in pipe is
8fL v2 8(0.02)(14) (0.45)2
hf = = = 𝟎. 𝟖𝟑 𝐦
D 2g 0.04 2(9.81)

Step 4: Total Head

The velocity flow in both suction and discharge side is the same. Thus through the
rearrangement of Bernoulli’s Equation, the total head is:
P2 −P1
hp = ( ) + (z2 − z1 ) + hf
ρg

3×105 −1×105
= ((941.81)(9.81)) + (10 − 0) + 0.83 = 𝟐𝟔. 𝟒𝟖 𝐦

Step 5: Power Required

Power required by the pump is based on the following equation:
1kW
Power = ṁghp = (8.33)(9.81)(26.48) = 107.26 W × 1000W = 𝟎. 𝟏𝟏 𝐤𝐖

Step 6: NPSHA
NPSHA only involves the suction side. Thus the length of pipe involved is only the suction side.
NPSHA is calculated with the following equation:
P1 −Pv
NPSHA = + z1 − hf1
ρg

Friction loss is calculated only on the suction side

8fL1 v2 8(0.02)(2) (0.45)2
hf = = = 0.12 m
D 2g 0.04 2(9.81)

1×105 −1×105
Thus, NPSHA = (941.81)(9.81) + 0 − 0.12 = 𝟕. 𝟎𝟏 m

For a pump to operate without cavitation, NPSHA > NPSHR. This requirement is checked for
the suitability of the pump. NPSHR is determined by using the following graph.
From the graph, volumetric flow rate of 1.58 m3/hr or equivalent to 6.95 gal/min gives
NPSHR of 5 ft or 1.52 m. Therefore, NPSHA > NPSHR. The pump is applicable.

Step 6: Actual motor power

The efficiency of the motor is determined in the graph above. From the graph, volumetric flow
rate of 1.58 m3/hr or equivalent to 6.95 gal/min and total head of 26.48 m or equivalent to 86.86
ft gives the efficiency of 0.22. Thus the actual power motor of the pump is:
0.11
Power = = 𝟎. 𝟒𝟗 𝐤𝐖
0.22

Converting into horsepower, hp

487.56 W x 1.341 x 10-3 hp/1 W = 0.65 hp or 0.64 bhp

Motor power that is chosen is 1 bhp.

4.2.1 Raw Feed Pump P-101

Design Criteria :

Pump (P-101) is design to transfer feed material of benzene from storage tank and recycle
stream to the reactor, R-101.

Design Basis :

Mass Flow Rate (kg/hr) 81789.20

Inlet Pressure (bar) 1.00
Outlet Pressure (bar) 8.10
Temperature (ᵒC) 64.97
Density (kg/m3) 832.44
Viscosity (Pa.s) 3.63E-04
Vapor Pressure (Pa) 65061.47

Design Parameters

I. Nozzle Design
II. Head loss, hp
III. Net positive suction head, NPSH
IV. Power Required

Design Method

The pump calculation is based on Coulson and Richardson’s Chemical Engineering Design

Type of Pump

Centrifugal pump
Material of Pump

Carbon Steel

Design Calculation:

Step 1 : Nozzle Design

Find the optimum diameter , DFind the optimum diameter , Dopt from Harker’s equation
(1978).

𝑚𝑎𝑠𝑠 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒,𝑚0.45

Optimum Diameter , Dopt = 8.41 𝑥 𝑠𝑜𝑙𝑢𝑡𝑖𝑜𝑛 𝑑𝑒𝑛𝑠𝑖𝑡𝑦,𝜌0.31

81789.20 0.45
= 8.41 𝑥 832.440.31

= 169.90 𝑚𝑚

= 6.69 𝑖𝑛𝑐ℎ

The nominal pipe size is calculated by referring Table 38 : Schedule 40 Pipe Dimensions
Based on the Dopt the nominal size choosen is 6 inch for schedule 40 pipe dimensions

Choosen Nominal size (in) 6

External Diameter (in) 6.625
Internal Diameter (in) 6.065
Nominal Thickness (in) 0.28
Area of Pipeline (m2) 0.0186

0.0254 2
𝜋𝐷 2 𝜋𝑥(6.065𝑖𝑛 𝑥 )
The area of pipeline , A = = 𝑖𝑛
= 0.0186 𝑚2
4 4

Step 2 : Calculate the liquid velocity

𝑘𝑔
𝑚 81789.2 ⁄ℎ𝑟 𝑚3
Volumetric flow rate, Q = = 𝑘𝑔 = 98.25 ℎ𝑟
𝜌 832.44 ⁄ 3
𝑚

𝑚3
# Centrifugal pump at the capacity range of 0.25-103 ℎ𝑟 .

Velocity of the liquid

3
𝑄 98.25𝑚 ⁄ℎ𝑟 1 ℎ𝑟
Velocity, v = = 𝑥 3600 𝑠 = 1.464 𝑚/𝑠
𝐴 0.0186𝑚2

Step 3 : Head loss, hp

Assume no change in velocity, Δv = 0

𝑘𝑔 𝑚 0.0245 𝑚
𝜌𝑣𝑑 832.44 ⁄ 3 x 1.46 𝑥 ( 6.065 𝑖𝑛 𝑥 )
𝑚
Reynolds number = = 𝑠 1 𝑖𝑛
= 5.18 𝑥 105
𝜇 3.63 𝑥 10−4 𝑃𝑎.𝑠

Absolute roughness, ε of carbon steel is 0.02 mm

0.02𝑚𝑚
Relative Roughness, ε/d = 25.44 𝑚𝑚 = 1.3 𝑥 10−4
( 𝑥 6.065 𝑖𝑛)
1 𝑖𝑛

Friction factor, f is 0.004 (from figure 5.7)

Length at both the suction and discharge side of the pump is at least 5 times the diameter of
the nozzle.

Length of suction side = 0.77 m

Length of discharge side = 0.77 m

Total length of pipe = 0.77 m + 0.77 m = 1.54m

8𝑓𝑙 𝑣 2
Friction loss =
𝐷 2𝑔

hf = 0.03496 m

∆𝑃
Total head loss, hp =𝜌𝑔 + ∆𝑧 + ℎ𝑓

Where ΔP is the pressure between inlet and oulet stream, Δz is the height difference between
suction head and tank head.
Assuming z1 = 0.5 m (from the ground)

z2 = 1 m (from the ground)

Total head loss, hp = 87.479 m

Step 4 : Net Positive Suction Head, NPSH

Its involved at the suction side of the pump. Therefore, the length of the pipe is only used at
the suction side length.

𝑃1 −𝑃𝑉
𝑁𝑃𝑆𝐻𝐴 = [ ] + 𝑧1 + ℎ𝑓1 = 4.76 m
𝜌𝑔

𝑚3
From the table given, the NPSH required of the pump is 1.83 m at the flow rate 98.25 ℎ𝑟 .

NPSHA is higher than NPSHR, the pump is applicable.

Step 5 : Power Required

Based on the Figure 10.62 ( from Coulson and Richardson’s Chemical Engineering Design),
the efficiency of the centrifugal pump, np is at 75 %.

Fluid power, P =(𝑚𝑔ℎ𝑝 ) ̇= 19496.89 W

Power required =(𝑚𝑔ℎ𝑝 ) ̇/𝑛p = 25995.85 W = 25.9959 kW = 34.8610 hp

 4.2.2 Raw Feed Pump P-102

Design Criteria :

Pump (P-102) is design to transfer feed material of Olefin from storage tank stream to the
reactor, R-101.

Design Basis :

Mass Flow Rate (kg/hr) 17499.49

Inlet Pressure (bar) 1.00
Outlet Pressure (bar) 8.10
Temperature (ᵒC) 28.00
Density (kg/m3) 742.7513
Viscosity (Pa.s) 1.11E-03
Vapor Pressure (Pa) 37.9441

Design Parameters

V. Nozzle Design
VI. Head loss, hp
VII. Net positive suction head, NPSH
VIII. Power Required

Design Method

The pump calculation is based on Coulson and Richardson’s Chemical Engineering Design

Type of Pump

Centrifugal pump

Material of Pump
Stainless Steel

Design Calculation:

Step 1 : Nozzle Design

Find the optimum diameter , DFind the optimum diameter , Dopt from Harker’s equation
(1978).

𝑚𝑎𝑠𝑠 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒,𝑚0.45

Optimum Diameter , Dopt = 8.41 𝑥 𝑠𝑜𝑙𝑢𝑡𝑖𝑜𝑛 𝑑𝑒𝑛𝑠𝑖𝑡𝑦,𝜌0.31

17499.490.45
= 8.41 𝑥 742.75130.31

= 87.94 𝑚𝑚

= 3.5 𝑖𝑛𝑐ℎ

The nominal pipe size is calculated by referring Table 38 : Schedule 40 Pipe Dimensions
Based on the Dopt the nominal size choosen is 3.5 inch for schedule 40 pipe dimensions

Choosen Nominal size (in) 3.5

External Diameter (in) 4.000
Internal Diameter (in) 3.548
Nominal Thickness (in) 0.226
Area of Pipeline (m2) 0.0064

0.0254 2
𝜋𝐷 2 𝜋𝑥(3.548𝑖𝑛 𝑥 )
The area of pipeline , A = = 𝑖𝑛
= 0.0064 𝑚2
4 4

Step 2 : Calculate the liquid velocity

𝑘𝑔
𝑚 17499.49 ⁄ℎ𝑟 𝑚3
Volumetric flow rate, Q = = 𝑘𝑔 = 23.5604 ℎ𝑟
𝜌 742.7513 ⁄ 3
𝑚

𝑚3
# Centrifugal pump at the capacity range of 0.25-103 ℎ𝑟 .

Velocity of the liquid

3
𝑄 23.56𝑚 ⁄ℎ𝑟 1 ℎ𝑟
Velocity, v = = 𝑥 3600 𝑠 = 1.026 𝑚/𝑠
𝐴 0.0064𝑚2

Step 3 : Head loss, hp

Assume no change in velocity, Δv = 0

𝑘𝑔 𝑚 0.0245 𝑚
𝜌𝑣𝑑 742.7513 ⁄ 3 x 1.03 𝑥 ( 3.548 𝑖𝑛 𝑥 )
𝑚
Reynolds number = = 𝑠 1 𝑖𝑛
= 6.17 𝑥 104
𝜇 1.11𝐸−03 𝑃𝑎.𝑠

Absolute roughness, ε of stainless steel is 0.015 mm

0.015𝑚𝑚
Relative Roughness, ε/d = 25.44 𝑚𝑚 = 0.000166446
( 𝑥 3.548 𝑖𝑛)
1 𝑖𝑛

Friction factor, f is 0.0032 (from figure 5.7)

Length at both the suction and discharge side of the pump is at least 5 times the diameter of
the nozzle.

Length of suction side = 0.45 m

Length of discharge side = 0.45 m

Total length of pipe = 0.45 m + 0.45 m = 0.9 m

8𝑓𝑙 𝑣 2
Friction loss =
𝐷 2𝑔

hf = 0.013717531 m

∆𝑃
Total head loss, hp =𝜌𝑔 + ∆𝑧 + ℎ𝑓

Where ΔP is the pressure between inlet and oulet stream, Δz is the height difference between
suction head and tank head.
Assuming z1 = 0.5 m (from the ground)

z2 = 1 m (from the ground)

Total head loss, hp = 97.956 m

Step 4 : Net Positive Suction Head, NPSH

Its involved at the suction side of the pump. Therefore, the length of the pipe is only used at
the suction side length.

𝑃1 −𝑃𝑉
𝑁𝑃𝑆𝐻𝐴 = [ ] + 𝑧1 + ℎ𝑓1 = 14.21 m
𝜌𝑔

𝑚3
From the table given, the NPSH required of the pump is 3.5 m at the flow rate 23.56 ℎ𝑟 .

NPSHA is higher than NPSHR, the pump is applicable.

Step 5 : Power Required

Based on the Figure 10.62 ( from Coulson and Richardson’s Chemical Engineering Design),
the efficiency of the centrifugal pump, np is at 65 %.
Fluid power, P =(𝑚𝑔ℎ𝑝 ) ̇= 4671.12 W

Power required =(𝑚𝑔ℎ𝑝 ) ̇/𝑛p = 7186.34W = 7.1863 kW = 9.6370 hp