FLUIDFLOW3

Application Note 03

DESIGN AND SIMULATION of MINE PUMPING

AND FLUID FLOW SYSTEMS

This note describes the application of the FluidFlow3 software package to the design and
simulation of all types of mine pumping systems including:
 Mine dewatering using submersible and end-suction centrifugal pumps (also
PD pumps).
 Bore farms using borehole pumps.
 Process flows using end-suction centrifugal and positive displacement pumps
 Spray/sprinkler systems such as dust suppression and fixed fire protection.
 Simulation of the hydraulic performance of control valves, heat exchangers,
orifice plates and almost any type of line equipment.
 Water and slurry* flow.
 Compressed air flow.

FluidFlow3 is a Windows-based software package for the simulation of flow through complex
pipe systems. The program calculates flows and pressures throughout the pipe network as
well as the performance characteristics of pumps, fans, control valves and other line
equipment. FluidFlow3 is extremely easy to use and has a range of powerful features
including: -
 An advanced graphical user interface allowing almost intuitive interaction with
even the most complex models.
 A highly effective data management system comprising user-definable
equipment and fluid properties databases.

FluidFlow3 can simulate the performance of multiple pumps and fans in series, parallel or
booster configuration. It is ideal for the investigation of existing systems prior to upgrade or
extension and the design of new systems.

A typical mine dewatering system may involve multiple pumps, say submersible dewatering
pumps supplying direct to tanks or dams or to booster centrifugal pumps. For a processing
plant the system may be a cooling water circuit supplying multiple facilities or the internal
process flows within the facilities. The gas flow module of FluidFlow3 will simulated
compressed air and ventilation systems as well as any other type of compressible flow such
as natural gas, steam etc.

GENERAL PUMPING DESIGN

Pump Database

FluidFlow3 allows users to enter and save an unlimited number of pump curves (say based
on manufacturers’ names). The following pump data can be entered:
 Pump name, model, nozzle sizes, materials, applications etc
 Capacity curve
 Efficiency curve
 NPSH curve
 Operating speed and impeller diameter
 Maximum and minimum speed and impeller diameter
 Maximum and minimum flow
 For PD pumps – displacement volume/rev, slip data etc
Piping Model

The pipe system is “built” in a typical flowsheet format, either in orthogonal or isometric
format, with pipes and line equipment data copied from the database or entered by the user
direct.

Once the system model has been built and the pump or pumps selected, the program will
calculate flows and pressures throughout the system. The following can be performed:

 Pumps can be switched on and off.

 Pump speed and impeller diameter can be changed within the model and the
affinity laws applied to the entered pump curve.
 The Hydraulics Institute correction for viscous fluids in end-suction centrifugal
pumps can be applied.

After calculation the software may generate the following warnings:

 Inadequate NPSH.
 Pump(s) operating outside set limits of minimum and maximum flow.
 Negative pressures or vapourisation of flow in the pipe system.
 Pipe velocities outside user-defined limits
 Any line equipment operating outside user-defined limits.

Full user-definable reports can be generated and these can be exported to Excel or printed
Word, PDF or HTML format.

BORE FARMS

FluidFlow3 is ideal for the design, analysis and on-going monitoring of the performance of a
borefarm.

The software allows the simulation of multiple bore pumps with pumps turned on/off to
replicate operational conditions. Once the model has been constructed, it is simple to
perform “what if?” calculations. Bore levels can be changed, different types of pipe and size
investigated. FluidFlow’s visual display of results and especially the instant display of pump
curves and duty points provide the engineer with a ‘snap shot’ of how the system will perform
under specified conditions.

TYPICAL PROJECTS

Accutech has used an earlier version of FluidFlow3 for the following mine-related pumping
projects:

Ulan Coal Mines: Simulation of multiple Pleuger pumps dewatering the decline by
pumping vertically through boreholes to a discharge main on the surface and
onwards to dams.

Springvale Coal: Simulation of large numbers of air operated and traditional end-
suction centrifugal pumps for dewatering by pumping along the decline to the surface.
Simulation of mine compressed air supply.

Mount Whaleback Mine: Simulation of multiple borehole and end-suction centrifugal

pumps for the dewatering of an open cut.
NON-NEWTONIAN AND SETTLING SLURRY FLOW*

All the above refers to Newtonian flow, eg clean water or dirty water containing small
amounts of solids which can nevertheless be regarded as Newtonian. Pipe friction losses
are calculated using a Darcy-type method.

For mineral slurries where the flow velocities are kept above settling, this may be a
reasonable assumption; maybe using the density of the mixture but the viscosity of the
carrier fluid (water). The performance of end-suction centrifugal pumps may need to be
modified to account for solids.

A separate non-Newtonian / Settling Slurry module of FluidFlow3 adds the following

capabilities:

 Friction loss model of Newtonian slurries

 Friction loss model of heterogeneous settling slurries.
 Friction loss model of non-Newtonian fluids and homogeneous non-settling slurries.
 Extensions to the fluid database to include non-Newtonian fluids whose viscous
properties can be described from viscometry data, from known constants
(Pseudoplastic, Dilatant, Yield Pseudoplastic and Bingham Plastic) or direct from
Shear Stress v’s Shear Rate data.
 Provide extensions to the fluid database to include data for solids and solid size
ranges.

The calculation methods include:

1. For heterogeneous settling slurries:

a. Durand
b. Wasp
c. Wilson, Addie and Clift
d. Darby/Molerus (Chemical Engineering Fluid Mechanics – 2001 ISBN 0-8247-
0444-4) p449
2. For non-Newtonian fluids and homogeneous non-settling slurries:
a. Darby p170-184 (Chemical Engineering Fluid Mechanics – 2001 ISBN 0-
8247-0444-4)

Not included at this stage is the combining/mixing of Newtonian and non-Newtonian fluids.

* Due for release end of November 2006.

ACCUTECH 2000 PTY LTD

Accutech is based in Perth, Western Australia and has been marketing and supporting fluid
flow software for nearly 20 years. We also perform pumping design using our software and
have conducted literally hundreds of designs of pumping and pipe flow systems.