Chapter 13 Pumping and Compression Lizuthantgses zee be pesuzed for waster toachieve the required pressure ofthe destination, overcome the pressure ‘drops in equipment and pipelines through which the material neds to be transierred to reach its destination and to overcome the ‘change in elevation. The cost ofa pressure increase for liquids in ‘pumps is usually small relative to that for gasesin compressors, On the other hand, to increase the pressure of material inthe gas phase in a compressor tends to have a high capital cost and large power requirements, leading to high operating costs, 13.1 Pressure Drops in Process Operations ‘When transporting material trough the process, the pressure drop through reactors, separators, heat transfer equipment, control valves, and other devices must be overcome. ‘For gas-phase reactions, the pressure drop through the reactoris| usually less than 10% of the inlet pressure (Rase, 1990). The pressure drop through trickle-bed reactorsis usually less than 1 bat. A valueof 0S bari often areasonable ist estimate for packed and ‘tickle-bed reactors, although pressure drops can be higher. The pressure drop through fluiized-bed reactors is usually between (002 and 0.1 bar. A pressure drop across distillation involves a pressure drop across each tray of typically 0.007 bar. A pressure drop across isillation packing is normally lower than for distillation trays for the same separation, Structured packing normally has a pressure drop les than 0,003 bar m Heat exchangers for liquids normally have a pressure drop in the range 0.35 to O.7bur (see Chapter 12). For gases, heat exchangers have a pressure drop typically between Ibar for high-pressure gases (10 bar and above), dowa to 0.01 bar for pases under vacuum conditions (see Chapter 12). Chemical Proce Design and Integration, Second Elton. Robin Sith 1 2016 fon Wiley & Sons, Lid. Pabished 2016 by John Wile & Sons, Li ‘Companion Website: www wiley somigofmitvchemicae 13.2 Pressure Drops in Piping Systems Consider the pumping of a liquid between two vessels, as illus- trated in Figure 13.La. Ifthe fuid is assumed to be incompressible and the change in kinetic energy from inlet to outlet is neglected, then the pressure change required to be delivered by the pump is given by: Pump read =P PO ga my aD Pe where AP = pressure increase across the pump (nr?=kga's) p= fluid density (kg.m™) {= gravitational acceleration (9.81 ms") Py = pressure atthe liquid surface in the discharge vessel (Nm) Py = pressure atthe liquid surface in the feed vessel my ‘Ag = change in elevation (m) Sh, = sum of the frictional head losses for straight pipes and pipe fittings (rn) Pipe ftings include bends, isolation valves, control valves, orifice plates, expansions and reductions. Ifthe material to be transferred is a ‘gs, aillustated in Figure 13.1b, te change in elevation can normally bbeneglected. I'he gas is assumed tobe incompressible andthe change in kinetic energy from inlet to outlet is neglected, then the pressure change required to be delivered by the compressor is given by: an_ (=P) a +Du a ae For straight pipes (Coulson and Richardson, 1999) ‘Compressor head L ae hy =2ey «3a where ¢j = Fanning fiction factor E = pipe length m) 4d, = internal diameter of pipe (am) = mean velocity inthe pipe (ms!) 13350 Chemical Process Design and Integration (@) Pumping ofa iq between vessels Figure 13.1 ‘Presure change fora piping syste fr ii wane, ‘The Fanning friction factor is given by (Hewitt, Shires and Bott, 1994) Re < 2000 134) o46Re°? 2000 < Re < 20,000 (13.5) 6 =0.079Re-°*5 Re > 20,000 36, where Re Itshould be noted that Equations 13.5 and 13.6 apply to smooth pipes, whereas the pipes used for transmission of fuids usually hhave some surface roughness, which increases th friction factor. However, for shor uid transmission pipes, the overall frictional pressure drop is usually dominated by the frictional pressure drop in the pipe fitings (valves, bends, etc). Thus, for short transmis- sion pipes, there is litle point in calculating the straight pipe Irictional pressure drop accurately. Irthe transmission pipe is long (100m) and straight, then the Fanning fiction factor can be correlated as (Coulson and Richardson, 1999): 37 where e= surface roughness (m) Table 13.1 gives some typical values of surface roughness (Coulson and Richardson, 1999). ‘Many different types of fitings are used in process pipelines. ‘When transporting fluids, valves are required for: ‘© starting and stopping flow (Block valve), © regulating the low (control valve, © preventing reversal of flow (nonreturn of check valve). Discharge esse » ood Pe ‘compressor () Compression ofa gas between vessels Figure 13.2 shows some of the more common types of valve used in the process industry. 1) Globe valve. Atypical globe valveisillustrated in Figure 13.2 A screw mechanism is used to move aplg ordisc against seat Figure 13.2a shows bothaaplug disc anda composite disc design, ‘The composite dise design uses a seating material incorporated into the dise and has some advantages in the way the dix guided tothe seat. Many different designs of seating arrange- mens are available. Globe valves can be used to regulate the flow, as well as stating and stopping the flow. 2) Butterfly valve. A typical butterfly valve is ‘lustrated in Figure 13.2b. The angle of a disc is manipulated relative to the flow. When the dise is perpendicular to the flow, a seal is ‘reated between the dise and the lining of the valve to prevent flow. When the discis oated through a quarter turn, the disci in line with the flow and the valve is open. Buttedly valves can be used to egulate the Bow, as wellas stating and stopping the low. ‘Their use is normally rescted to larger diameter pipelines 3) Gate valve, A typical gate valve is illustrated in Figure 13.2c ‘This operates by a screw mechanism raising and lowering ‘circular gate in the path ofthe uid. The gate faces can form a wedge shape or can be parallel. Gate valves are primarily used for starting and stopping Bow, rather than regulating the Now. Table 13.1 Surface roughness of pipes. awn hing 00015 Commer see 0.086 cast irom 026 Conere 0330Pumping and Compression 351 aN == =( (ote nn gag (6) sey ae (00a ne um r eve pa vave (0.svng pe sone (Pea (yaaa Sing Figure 13.2 vate pes, 4) Plug valve. A typical plug valve is ilustated in Figure 13.24. ‘A cylindrical or more often conically tapered plug with hhollow por is rotated through a quarter tum to allow or prevent low. The installation space is smaller than a gate valve and ‘operation to open and close is simple and rapid. The tapered plug allows a tight shut-off, 5) Ball valve. A typical ball valve is illustrated in Figure 132e, A sphere with a cylindrical hollow port is rotated through a quarter ‘turto allow or prevent flow. Conventional ball valves have aport ‘smaller than the pipe diameter. Fall port valves with the same diameter ofthe pipe ae also available, ut are less common, Tight ‘shut-off can be achieved by virtue of the seat rings, but the seat ‘material ereates temperature imitations. As with plug valves ball ‘valves require an installation space smaller than a gate valve and ‘operation to open and close is simple and rapid. 6) Nonreturn (check) valve, Nonretur valves ate used purely to prevent reversal of flow, for example to prevent liquid from siphoning back from a tank if pump is switched off. A swing- type nonreturn valve is ilustrated in Figure 13.2F. The dise ‘swings on ahinge ether onto the sea to prevent reverse flow or swings to allow forward flow. Other designs of nonretum valves use mechanisms such as forward flow moving a ball ‘mounted in a slot moving away from a circular seat to open the valve with reversal of flow moving the ball in the reverse izection to seal with the seat to prevent reverse flow. ‘Control valves are used to contol low, pressure, temperature and liquid level by opening and closing in response to signals, ‘received from controllers The opening or closing of contol valves ‘occurs remotely by an detuafor. Actuators can be pneumatic or clecrical. Most control valves inthe process industry use a globe valve design. The plug and seat are shaped to vary the opening acconding to the desired contol characteristics, Figure 13.3 illus- trates a pneumatically operated control valve. An air pressure signal ‘that varies between 0.2 and I bar causes the valve to open or close. Air Pressure Sign i Flexible Dispsam Z Diaphragm Plate Actuator Fal Actuator Spring em Sea Figure 13.3 ‘Schematic arangement ofa peumatclly operated conel vale352 Chemical Process Design and Integration ~~, bee — (a) sen comraston, Figure 13.4 Pipe fittings. Foran electrical actuator using an electric motor, an electrical signal between 0 and 10V or between 4 and 20mA causes the electric ‘motor to open or close the valve. If there is failure, the valve _mustbe designed such thatthe most probable failure mode results the safest condition, known as the ail safe condition. The fil safe ‘condition might be fully closed, fully open or to maintain the current valve position to maintain the current operation, The valve design in Figure 13.3 will open if the air signal fails. diferent arrangement ‘with the spring and diaphragm inverted can create a design that loses ifthe air signal fails. Many other contol valve designs are available with different actuators In addition to valves, other fittings include sudden contraction, sudden enlargement, bends and orifice plates used for low mes- surement (Figure 13.4), The head loss in the pipe fittings can be correlated as (Coulson and Richardson, 1999): (138) where cz =loss coefficient (~) Table 13.2 Loss coeflcients for vasous pipe figs. ‘Bend Gandand) Giobe valve (plug ise) ‘Globe valve (compaite sea) ate valve Prog valve Ball valve Busty valve [Nonretm valve wing) (0 Salen expan Prosar Tp wo (Oris pa For laminar flow. (Re, geometry of fiting) For turbulent flow: c= flgeometry of fitting) Table 13.2 gives some typical values of the loss coefficient for valves and othe tings (Perry, 1997) tshould be noted that values for loss coefficient for the same fitting, but from different manutac- turers, will vary as a result of differences in geometry. Table 13,3, ives head losses for sudden contractions, sudden expansions and orifice plates. Note thatthe formula for orifice plates in Table 13.3, relates to the overall pressure drop and not the pressure drop between the pressure tappings used to measure the flowrate In preliminary design, the fluid transmission lines can be {signed on the basis of an assumed fuid velocity, For nonviscous, Tiguids (< 10mN-s:m"? =: ct is normally used. For viscous uids, the velocity may be -), a pipe velocity of 1 to 2ms’ ee ieTable 13.3 Head loses in sudden contractions sudden expansions and orice plates. Mee | fo) = [-a@ mem sh ‘Ay Aas upsteam and downsteam pie aes *) accelration dv to gravity © m5) 162 for preliminary design constrained by the allowable pressure drop or shear degradation of the fluid (eg. large molecules breaking down into smaller moleules from high shear rats). Typical values are given in Table 13.4 For gases and vapors, typical uid velocities ae inthe range of 15 to 30m" Table 13.5 ‘Commonly used sandal pipe sizes for ste! pipes. 15 2134 1808 ma 2» 2661 2337 2245 23 240 30.10 2786 2 4216 886 3682 © 4826 4496 an so 33 S703 3479 6 7303 oa 93 %0 550 8808 3280 100 11430 not 1082, 10 16828 1627 sis 20 21908 ass a6 250 27305 2862 2687 300 33.85 ais, 3147 Pumping and Compression 353, Table 13.4 ‘Typical id velocities for viscous liquids 0 oso 100 0206 1000 1-03 ‘The fluid velocity must take account of standard pipe sizes, Pipe sizes are specified by # nominal pipe size (NPS), or nominal diameter (DN), and aschedule. The larger the schedule number, the thicker the pipe wall, Table 13.5 gives dimensions for a number of. commonly used pipe sizes. The schedule of pipe required depends fon the maximum intemal pressure and the appropriate corrosion allowance, For steam systems, the smallest schedule normally used is Schedule 40. the piping ayout is known, then the above correlations can be ‘used to estimate the pressure drop through the pipes. This might be the case, for example, ina retrofit situation. In preliminary design, it might be necessary to make some allowance for the cost of ‘pumping and compression without knowledge of the piping layout. [thisis the cas, then iti not difficult to make a rstestimate ofthe distances required for wansportaton ofthe uid. What is uncertain 1631 1540 1387 1179 a1as 2n93 18s 1554 261 2568 23 2070 3622 3805 246 2346 ais 089 2810 3399 53.98 5231 4926 291 6348 an 901 5398 1935 ns 1366 66s 104s 1023 ors 33 1581 463 1318 2050 2m 1937 mu 278 2385 209 2159 sor 3088 2889 2012 13Chemical Process Design and Integration is the pipe fittings that will be involved. Some general guidelines are therefore required in onder to make a frst estimate of the pressure drop to lake account ofthe pipe fitings: '© Vessels will often have isolation valves (but this varies between different sectors of the industry) (© Equipment that needs to be taken out of service for maintenance will normally have an isolation valve on each side. This will include pumps, compressors and control valves. ‘¢ Insome situations, for the sake of process safety, a more secure isolation is required on inlets and outlets. In this ease, double block and bleed can be used. This involves two isolation valves With a vent valve between them. By closing the two isolation valves and opening the vent valve between them, any leakage past the upstream valve will go through the vent instead of Potentially leaking through the downstream valve, ‘© Pumps will normally have a nonretumn (check) valve to prevent reversal of flow ‘© Flow control will usually be based on the measurement of pressure drop across an orifice plate. © A line going between vessels or between a vessel and a pipe junction will typically have atleast three bends when the pipe design is finalised. Forexample, suppose a liquid is being pumped from one vessel into another vessel using a pump and under the action of flow control using an orifice plate to measure the flowrate, The head losses involved will ypicaly be: ‘© a sudden contraction from the feed vessel into the discharge lines an isolation valve for the vessel two isolation valves and a check valve for the pump; an orifice plate for flow measurement; 1 control valve; two isolation valves for the control valve; typically three pipe bends from changes in direction of the pipes: an isolation valve for the discharge vessel; ¢ a sudden expansion for the Guid entering the discharge vessel, Example 13.1 Inancw design, water istobe pumped between two vessels both at atmospheric pressure separated by an estimated distance of 30m under the ation of flow control. An increase in elevation of Sm is also estimated, The flowrate of water is 100m", its viscosity is 0.8mN-sin-? (equal to centipoise) nd its density is 993 kg-m”. Estimate the pressure drop required to be produced by the pump. Solution First determine the pipe diameter from an assumed velocity of say 2ms~!. The area ofthe pipe (A) is given by: 1a A= 10055 = 0.01389 m? ‘The internal diameter (d) is piven by = 033m, ‘This needs to be rounded tothe next largest standard pipe diameter of intemal diameter. Assuming a Schedule 40 pipe this would be (0.154, The actual Guid velocity is therefore: 1 4 8 O60 0S = 149m.st [Reynolds number fr the straight pipes is Rew # 93x 0.154 x 1.49 = osx107 = 2.85% 10° Head loss inthe straight pipe sections: FForthe isolation valves, ake gate valves full opea, one for each ‘vessel, two for the pump and two for the control valve hy = 6x0 2% Last =6x02x nT = 014m Assume & nonretum (check) valve forthe pump: hea Lag? = 2,087 = 023m ‘To estimate the control valve, tke a globe valve tobe half open: 9 os’! 2x98T = 365m ‘Assume three bends Last hy = 3x08x = 027m‘Assume an orifice plate to measure the fowrate with a diameter ratio of 04 and discharge coefficient of 0.62 Ao} neg) e 1 2 “ ig = saat-01[() =m = 941m ‘The entrance loss from the feed vessel is given by: Al) ne os] 1497 + oom The exit loss into the receiving vessel is given by: 2 a 1492 ers = 011m AP (-P) = +a2+ oh mom eh ‘Because both the feed and discharge tanks are at atmospheric pressure (P) ~ P)) = 0: Pump Pumping and Compression 1+5-+(0,30+0.14-40.23+3.65+0.2749.41+0.0640.11)] =19.17m 139.81 «19.17 13.3 Pump Types Pumps can be classified into two general types: 1) Positive displacement, In positive displacement pumping energy is transferred tothe liquid by tapping a fixed volume and forcing the trapped volume to the pump discharge in srrangements such as reciprocating pistons, or rotary motion of gears, screws of vanes. Positive displacement pumps deliver 1 definite quantity for each stroke or partial rotation of the device. They are used when the liquid has a high viscosity, low owrate, or a combination of the two. Dynamic. In dynamic pamps energy is transferred tothe liquid by means of vanes mounted on a rotating shaft. The liquid enters along or near the rotating shaft and is accelerated by the rolation ofthe vanes, This imparts kinetic energy to the liquid, Which is transformed to pressure energy 2 The most common type of pump used in chemical processes is ‘centrifugal, Ths is & form of dynamic pump in which an impeller consisting of curved vanes rotates on a shaft, The arrangement is illustrated in Figure 13.Sa. The liquid enters near the rotating axis, (6) Open impel 355, 13 \ (0) How pater, (4) Closed imp. Figure 13.5 ‘Ceiugal pump fetes