By:Abdullah Al Bin Saad

Hydraulic Calculation
Hydraulic
(Basics Calculation
of single Phase)
(Basics of single Phase)
 Hydraulic Calculation
(Part-2 Basics of single Phase)
By:Abdullah Al Bin Saad

Hydraulic Calculation
(Basics of single Phase)
Agenda

• Overview

• Hydraulic basics

• Introduction to Piping Drawings

• Work steps

• Required documents

• Hydraulic Design

• Calculation tools

• Guidelines for practical line sizing

Overview

 What is hydraulic?
• Pressure balance of fluid in a system
• Describes the flow of fluid through a system
 How fluid move?

3 barg Atm

Gravity
Difference in Pressure
Overview

 Why do we need hydraulics?

♦ To make sure that fluids reach the required destination at the required conditions
♦ Determine the line size
♦ Pump & Compressor Differential pressure
♦ Elevation of Equipment
♦ Control Valve Pressure Drop
Hydraulic basics

 Will fluid flow?

Yes
Hydraulic basics

 Will fluid flow?

NO
Hydraulic basics
 Fluids will lose some pressure due to :
 Fraction in pipelines

Le  DP  Dia  DP 
 Instruments (i.e. orifice)
 Fittings (i.e. elbows,bends,tees)
 Equipment's (i.e. heat exchangers, filters)
 Piping Components (i.e. strainers)
Introduction to Piping Drawing (Plot Plan)
Introduction to Piping Drawing (Isometrics)
Introduction to Piping Drawing (PMS)
Introduction to Piping Drawing (Equivalent len. )

Pipe Size : DN100 (4") L​eq​​=20×102.3 mm=2.046 m

Pipe
Diameter : 102.3 mm
L​eq​​
Pipe =17×102.3 mm=1.739 
L​eq​​=50+2.046 mm=52.05 m
: 50 m
Length m
3 x 90° long radius)
Fittings :
elbows
Work steps

♦ Define system
♦ Collect all available required documents
♦ Draw system sketch
♦ Gather all required data (input data)
♦ Input data to software tool (Hydra)
♦ Analyze output data as per engineering guidelines (Velocity-∆P)
♦ Check the results with client’s criteria & limitations
Required Documents

♦ Process Flow Diagram Process Data (P,T, Sp.Gr.,Visc..etc)

♦ Piping and Instrument Drawing System Sketch
♦ Plot Plan Preliminary length in DBSP & Feed Stage.
♦ Isometrics (if available) Exact length & fittings
♦ Equipment data sheet Pressure Drop &Vapor Pressure
♦ Piping material specification Inner Diameter
Hydraulic design ( System Sketch)

Pressure

Eq. length Elevation

Instruments

Line # and
Size
Hydraulic design (Input Data)

Required Data

Process Data:
Flow rate -Pressure
Temperature- Service
Physical properties Design Requirement:
Liquid service: Piping Data: Marginal head of the pump NPSH available, if any
Density, Viscosity, Vapor pressure, Critical pressure, SpGr Line class-Length- Elevation-Fittings - Over design % - specification of the design flow rate, if
Equipment any
Vapor service: - Turndown % - specification of the minimum flow rate, if
Density, Viscosity, Molecular weight, Specific Heat Ratio any
(Cp/Cv),Compressibility Factor (Z)
Two-phase flow:
Densities and Viscosity for both liquid and vapor and
Surface tension
Hydraulic design (Process Data)

♦ Fluid name
♦ Flow rate
♦ Pressure
♦ Temperature
♦ Service
♦ Physical properties (Viscosity, Density, Vapor pressure, Specific
Heat Ratio (Cp/Cv),Compressibility Factor (Z) and Surface tension)

All those data can be taken from process flow diagram (H&MB).
Hydraulic design (Piping Data)

♦ Pipe size :
 Except otherwise specified, DN 1¼", 2½", 3½", 5", 7", 9" and 22"
should not be used.
 The minimum process line size in pipe racks is 2". The minimum
pipe size is 3/4" except individual instrument leads, pump and
compressor auxiliary piping, etc.
 The velocity should be based on inner dimeter.

♦ Elevation:
 From plot plan (FEED Stage)
 From Isometrics (Detail Design Stage)
Hydraulic design (Piping Data)

♦ Equivalent length:
 At the early design stage of each project equivalent length can
be estimated as the following :
Process Line : straight length x 3
Rack Line : straight length x 1.5
Where :
straight length: length measured in plot plan ( the sum of XYZ )
 Equivalent length takes account for straight length plus fittings.
 At Detail Design stage, straight length and fittings should be
obtained from Isometrics.
Hydraulic design (Model Output)

Output From
Hydraulic

Equipment Pressure
Line Size
Elevation Balance
Hydraulic design (Press. Drop )

 Most of calculation tools use Darcy-equation so it will be

presented here.
Le 1
P  f  V 2
D 2
Where :
∆P : Frictional Pressure drop (Pa) ƒ : Moody's friction factor
Le : Equivalent length (m) ρ : the density of the fluid (kg/m3)
D : Internal diameter of the pipe (m) V : the mean flow velocity (m/s)
Hydraulic design (Press. Drop )

♦ Moody's friction factor:

 Fraction factor can be taken from Moody’s chart or below
correlation.
 For laminar flow (Reynolds number below 2000) the friction factor
can be calculated as:
64
f 
Re
 For turbulent flow (Reynolds number above 4000) the friction factor
can be calculated using an equation developed by C.F Colebrook:

1   2.5226 
 2.0  log  
f  3 .7065  D Re f 

Hydraulic design (Press. Drop )

 Where:
= pipe inside roughness given in Table A1-2 (m)
Unless otherwise specified, the roughness of commercial steel
pipe, = 0.0457 mm = 45.7 x 10-6 m should be used for process
piping.
Hydraulic design (Press. Drop )

At the early stage of projects , no data are available regarding how

much pressure drop will be in equipment, instruments as well as
piping components. So, process engineers use typical pressure drop
for the following :
Estimated pressure drop of equipment
Estimated pressure drop of instruments
Estimated pressure drop of piping components
Hydraulic design ( Press. Drop )

Estimated Pressure Drop of Equipment:

Hydraulic design ( Press. Drop )

Estimated Pressure Drop of Instruments:

Flow orifice 0.2 bar
Venturi tube 0.02 bar
Rotameter 0.2 bar

Estimated Pressure Drop Piping Components:

The pressure drop of a permanent strainer should be taken as follows.
0.5 m for dirty service
0.3 m for clean service
Calculation Tools

Hydraulic calculation will be done by one of the following software:

 Company Hydraulic Tool (Excel sheet )
 AFT Fathom (for net works)
 Pipe Phase (Pipeline)
 SPS Stoner (Pipeline)
 OLGA Dynamic Multiphase Flow Simulator (3 Phase)
 Aspen Flare System Analyzer (flarenet)
Guidelines for Practical Line Sizing

 Limitations of line sizing:

Erosional?
Sonic?

(Erosional)

 Limitations Values will be taken Form Client’s Standards or your

company guideline
Guidelines for Practical Line Sizing
Guidelines for Practical Line Sizing

♦ Sonic Velocity:
 The maximum velocity shall be less than 50% of the sonic
velocity for continuous gas or vapor services.
 It can calculated as :

g c kRT
Vsonic 
M
gc:Gravity conversion factor (kg ･ m/kgf ･ s2)
R: Gas constant 847.9 (kgf/m2)(m3)/(kg-mole)(K)
T: Temperature (K)
M: Molecular weight
Guidelines for Practical Line Sizing

♦Erosional Velocity
 The velocity above which erosion may occur in gas/liquid two-
phase flow can be determined using the following empirical
equation. (As per API RP-14E).
Ce
V  or  V 2 C 2
e m m e e

Where:
Ve : Erosional velocity (m/s) C e:Empirical constant (m/s)(kg/m3)1/2
pm :Homogeneous density(kg/m3)
 Hydraulic Calculation
(Part-2 Introduction to pumps)
By:Abdullah Al Bin Saad

Hydraulic Calculation
(Basics of single Phase)
Agenda

• Introduction to Pump

• Pump Selection

• Principle of operation (Centrifugal)

• Typical Centrifugal Pump curve

• Affinity Laws

• Pressure Balance around pump

• Pump design data

• Pump Data Sheet

• Evaluation of Existing Pump

Introduction to Pump

♦What is Pump :
 Pump is a device used to transfer non-compressible fluids from lower energy point to higher
energy point.

 Based on the principle of transferring energy to fluid, there are two basic types of pumps:
A) Centrifugal
B) Positive displacement
Pump Selection

♦The pump type selection is influenced by such factors as the fluid

characteristics, flow rate, required head.
Pump Selection

♦Selection of pump type should follow to previous Figure . However there are more aspects that
need to be considered:

♦Viscosity
 Centrifugal pump performance declines quickly with increasing viscosity, and a displacement pump is
usually the better choice whenever the liquid viscosity exceeds 110 cSt.

♦Energy consumption
 Positive displacement pumps have better efficiency than Centrifugal pump particularly those near the centrifugal pump upper limit.

♦Positive Displacement include rotating & reciprocating . So what would be the better choice :
 Reciprocating pump is preferable when liquids containing abrasive solids
 Reciprocating pump is the more appropriate selection when viscosity is low.
Principle of operation (Centrifugal)

 Main Components:

 Principle of operation :
The kinetic energy of the fluid increases from the center of the impeller to the tips of the impeller
vanes. As the fluid leaves the impeller vanes, the kinetic energy is converted into Head.
Typical Centrifugal Pump curve

 Important definitions:
 Minimum Continuous Thermal Flow:
The minimum continuous thermal flow is the lowest flow at which the pump can
operate and still maintain the pumped liquid temperature below that at which the
NPSHa equals the NPSHr.
 Minimum Continuous Stable Flow:
The minimum continuous stable flow is the lowest flow at which the pump can
operate without exceeding the noise and vibration limitations
 Shut-off head :
the differential head developed when pump discharge is shut off
 Best efficiency point:
The point at which pump efficiency peaks is called the best efficiency point or BEP. F

As per API, Pumps shall have a preferred operating region of 70 % to 120 % of best efficiency flowrate of the pump as furnished.
Rated flow shall be within the region of 80 % to 110 % of best efficiency flowrate of the pump as furnished.
Typical Centrifugal Pump curve

 Typical Pump Curve:

Typical Centrifugal Pump curve

 Typical Pump Curve:

Centrifugal Pumps Affinity Laws

 Affinity Laws:
Characteristic curves generally show pump performance for a fixed diameter impeller running at a fixed speed on a liquid of given
properties. The curve will be affected by a change in either the diameter of the impeller or the speed, and may be altered appreciably by
a change in the physical properties of the liquid pumped.
Relationship between pump parameters ( head, capacity, impeller diameter, power) is given in terms of affinity
laws.
These laws provide quick estimation of pump parameters for a specific impeller design if impeller size is
changed or pump speed is changed. Following are the equations from Affinity law;
Q 1 / Q 2 = D1 / D2
P1 / P 2 = (D1 / D2)3
H1/H2 = (D1/D2)2
Pressure Balance around Pump

Diff.Press = Pd - PS

PS = Op. Press + Static press- Prss. line loss – Press loss by other

Pd = Op. Press + Static press-+Prss. line loss + Press loss by other

Static press= (Sp.gr *elevation)/

10.2

Delta P

Pd
Ps
Pump design data

  Physical Properties :
o Density (kg/m3)
o Vapor Pressure (bar)
o Fluid type
o Temprature (Min, Nor & max)
 Flow Rate:
o Normal Flow : It shall be taken from HMB
o Rated Flow : It should be the normal flow rate plus some margin.
o Min Flow : Turndown
 Diff. Head :
ΔP=P discharge – P suction
Pump design data

 NPSHa:
– Centrifugal pump will damage if vapor get to the pump impeller.
– Cavitation is a momentary release of vapor and dissolved gas, as bubbles, followed by the collapse of these
bubbles . It occurs within the pump whenever the local pressure falls below the vapor pressure of the pumped
fluid and the pressure subsequently increases to above the vapor pressure.
– Cavitation damages the pump impeller.
– In design, we use the term NPSH (net positive suction head), to quantify the difference between pump suction
pressure and fluid vapor pressure.
– NPSH = Suction pressure in terms of head – Vapor pressure in terms of head.
– Keeping NPSH positive, theoretical eliminate the vaporization problem, however, pratically pumping fluid
experience further pressure drop when it goes inside the pump.
– Therefore, NPSH is kept somewhat above zero.
Pump design data

  NPSHa:
o Available NPSH (NPSHA) should always be exceed the pump's required NPSH (NPSHR) my 0.9 m (API).
o NPSHa is the net positive suction head available by system design.
o NPSHr is the required minimum NPSH by pump manufacturer.
o NPSHa is calculated by Process Engineer and NPSHr is provided by pump Vendor.
o Usually NPSHa – NPSHr > 1 m
o Some industrial practices require that the margin between NPSHa – NPSHr should be at least 2.0 m if the
liquid is below atmospheric pressure and 1.0 m if liquid is above atmospheric pressure.

 Maximum Suction Pressure

Max Suc= Design Press. of Source vessel +

o Maximum suction pressure is used for pump seal design.

Pump design data

 Maximum Shut-off Pressure

o Maximum shut-off pressure is used as design pressure for equipment and piping of centrifugal type pump
discharge system.
o There are two ways to estimate the above parameter
Maximum Shut-off Pressure= Max Suction Press+ Normal diff. of pump
Maximum Shut-off Pressure= Nor Suction Press+ Shut off (1.25 X Normal diff. of pump) (for motor)

When pump performance curve is available, check that shut-off differential pressure of pump is lower than
the estimated value. If shut-off differential pressure is higher than the estimated value, the following should
be considered.
- Increase design pressure of pump discharge system
- Provide safety valve
- Change to low shut-off pressure pump
 Design Temperature:
Design temperature should be determined based on upstream vessel.
Pump design data

 Pump Power:
o Hydraulic power is the power delivered to fluid.
o Hydraulic power = Ph(kW) = q ρ g h / (3.6 106)
o Brake Horse Power is the shaft power or mechanical power to be available at pump shaft
o Driver power is the power required for driving agent (Motor / Steam turbine).
o BHP = Hydraulic power / pump efficiency
o Driver Power = BHP / Motor Efficiency
o Pump efficiency is available on pump characteristic curve.
o Driver efficiency can be obtained from driver manufacturer data.
Pump Data Sheet

 Data sheet
Evaluation of Existing Pump

 If operating company need to do expansion project to increase production by 25%.

What will be the steps to evaluate the existing pump?
o Check whether you can reduce the dynamic loses in system (ie. the control valve is big and over designed so
you reduce the pressure drop to minimum acceptable value and still). So you can avoid changeling impeller.

o By the way, I have seen a lot of pumps that were over designed. Hence, you need to be careful when you
evaluate the hydraulic mode and always ask your client to provide you proper pressure survey to validate your
hydraulic model.

o The new parameters will be determined after building the hydraulic model(Head , Power & NPSHa)

o 2-Check that pump can give you the new head at max Impeller that has been mentioned by OME in data
sheet.

o Hint: Sometimes vendor do not put the performance curve of max impeller and they just put max impeller
diameter.
o Don’t panic and use affinity laws to estimate the head!
Evaluation of Existing Pump

 Do not forget Pump friend (control Valve) as they work as team. So, check the rangeability of control valve and
other things shall be checked by instrument engineer i.e. velocity and noise.

 Check the new NPSHa vs NPSHR (at the new capacity from pump curve) and ensure we have the minimum
margin which vary with fluid service (minimum 1 meter as suggested By API and could be 3 m if the service
was boiler feed water)

 Check the efficiency from curve @ revised duty point and calculate pump shaft to check that motor is
adequate (consult electrical engineer).
 Check the operating region of pump @ new duty point.
As API 610 Stated, a centrifugal pump's operating flow range can be divided into two regions:
Pumps shall have a preferred operating region of 70 % to 120 % of best efficiency flowrate of the pump
and Rated flow shall be within the region of 80 % to 110 % of best efficiency flowrate of the pump.
 6- Check the new design pressure based on new shut of head of new impeller or new pump.
 Eventually, always consult OME to confirm your recommendations and confirm other things such as adequacy
of base plate and the new requirement for cooling etc .
Evaluation of Existing Pump