Documente Academic
Documente Profesional
Documente Cultură
\
|
|
.
|
\
|
= 1
1000
2
L
s i
L d
D
g F V
Modified Durand Formula:
25 . 0
1
1000
2 25 . 1
|
|
.
|
\
|
|
|
.
|
\
|
|
.
|
\
|
=
L
s i
L d
D
g F V
For full pipe and fine slurry, settling velocity will be estimated with the
Wasp formula.
Wasp Formula
|
|
.
|
\
|
|
.
|
\
|
|
|
.
|
\
|
= 1
1000
2 '
6
1
50
L
s i
i
L d
D
g
D
d
F V
Where:
V
d
= Settling Velocity (m/s)
F
L
= f (d
50
, C
v
), according to graph of Mc Elvain and Cave.
F
L
= Correction factor (Wasp formula), calculated as: F
L
= 3.32
(Cv/100)
0.213
Cv = Volume concentration, %
D
i
= Internal diameter of pipe or flow height of launder (mm)
Project C-560
Design Criteria 000-GD-P-006
Piping Design Criteria
Rev. 2
Q:\Shared\R0534200\01_Eng_Doc\05_Pip\01_Design_Criteria\02_Int_App\000-GD-P-006 Piping Design Criteria\560-000-GD-P-
006_2.doc
Page 33 of 43
d
50:
particle diameter
such 50% by weight of the particles are smaller
than d
50
(mm)
g = gravity acceleration (m/s
2
)
s
= solid density (kg/m
3
)
L
= liquid density (kg/m
3
)
The normal criteria shall be V = 1.1 V
d
.
Slurry velocity shall not be greater than 6.0 m/s to minimize abrasion
in pipe / launder.
23.5.1.4 Free Surface Gravity Flows
For non frothing slurry, the free surface gravity flows shall be
calculated using the Manning formula. In considering the slurry
viscosity, the Manning coefficient (n), will be calculated relative to the
friction factor (f). Friction factor (f) will be calculated in accordance
with the Colebrook formula.
Manning coefficient
g
f
R n
h
8
6
1
=
Where:
R
h
= Hydraulic Radius (mm)
g = gravity acceleration (m/s
2
)
Colebrook Formula
(
(
+
|
.
|
\
|
=
f
D
e
f
Re
51 . 2
7 . 3
log 2
1
10
Where:
R
e
= Reynolds number
e = absolute roughness of pipe or launder wall.
R
h
= Hydraulic Radius (m)
When the pipe is full, then R
h
= Internal Diameter (ID) of pipe
For e, use the following values:
Material e (mm)
Steel 0.05 - 0.25
HDPE 0.025
Rubber 0.01 - 0.05
Concrete 0.3 - 3.0
Project C-560
Design Criteria 000-GD-P-006
Piping Design Criteria
Rev. 2
Q:\Shared\R0534200\01_Eng_Doc\05_Pip\01_Design_Criteria\02_Int_App\000-GD-P-006 Piping Design Criteria\560-000-GD-P-
006_2.doc
Page 34 of 43
23.5.1.5 Slurry Viscosity
For diluted slurry (concentration by weight less than 30%), the
calculation will be as per clear water.
For slurry concentration by weight = 30% - 65%, companies with wide
experiences in transport of slurry recommend values for the viscosity
considering the pH, which have given good results in slurry mining in
Chile and they are shown in the following table:
Kinematics Viscosity (10
-6
x m
2
/s)
% of solids (by weight) pH = 10 pH = 11
30 1.7 1.8
35 2.0 2.2
40 2.4 2.5
45 2.8 3.1
50 3.5 4.1
55 4.8 5.6
58 6.5 7.6
60 7.3 8.5
65 17.5 19.3
Note: The tabulated values are a compilation of
Chilean experiences in mining slurry.
23.5.1.6 Open Launders Shape Design.
For transport of slurries, a launder of semicircular bottom section is
the preferred design.
For equipment connection, sampling devices and other special
requirements, rectangular launder may be used in accordance with
Vendor recommendation of associated equipment.
23.5.2 Design Criteria for Gravity Flow of Slurry Without Froth
23.5.2.1 Flow Type
Typically, slurries with froth are concentrates produced by the flotation
process. Open launders are required for frothy slurry transport.
Slurry gravity lines shall have a continuous slope with adequate fall for
the design capacity and without low points/ pockets.
Project C-560
Design Criteria 000-GD-P-006
Piping Design Criteria
Rev. 2
Q:\Shared\R0534200\01_Eng_Doc\05_Pip\01_Design_Criteria\02_Int_App\000-GD-P-006 Piping Design Criteria\560-000-GD-P-
006_2.doc
Page 35 of 43
Where low points / pockets are unable to be avoided, valves purge
connections shall be provided.
23.5.2.2 Flow Depth
For flow of slurry with froth, free surface slurry gravity lines shall be
designed for flow depth of approximately 20% - 50% of launder width
(B) calculated with froth factor included. Refer Fig 3.
R
A
h
e
h
e
= 0.2B to 0.5B
B (or D)
Fig. 3
23.5.2.3 Settling Velocity (V
d
)
Refer 23.5.1 3).
23.5.2.4 Free Surface Gravity Flows
Refer 23.5.1. 4).
For frothy slurry, the calculation shall be made for maximum flow
increased by froth factor. The physical proprieties of slurry, specifically
the specific gravity and viscosity, shall not be modified.
23.5.2.5 Slurry Viscosity
Refer 23.5.1. 5
For concentrate launders
it is recommended
A = 6R = 3D
Project C-560
Design Criteria 000-GD-P-006
Piping Design Criteria
Rev. 2
Q:\Shared\R0534200\01_Eng_Doc\05_Pip\01_Design_Criteria\02_Int_App\000-GD-P-006 Piping Design Criteria\560-000-GD-P-
006_2.doc
Page 36 of 43
23.5.2.6 Open Launder Design
Refer 23.5.1 6).
23.5.2.7 Free Height in Launders
Refer 23.5.1 7).
23.5.3 Design Criteria For Non Froth Slurry Pumping
The settling velocity will be calculated by formula indicated in 23.5.1
3).
The flow velocity (V) shall be greater than the settling velocity. In any
event, the flow velocity shall not be greater than 6.0 m/s to minimize
abrasive wear.
The pressure drop shall be calculated using the Darcy formula,
whereas the Colebrook formula shall be applied for the friction factor
calculation. Alternately use Churchill according to the Chemical
Engineering (Fluid Dynamics).
For valves and fittings, pressure drop coefficients shall be derived
using the resistance coefficient K, as listed in industry publications
typically Crane or Cameron. The use of an equivalent length in lieu of
K is acceptable.
All values of friction losses not including H
s
shall have a design
margin of 5% - 10% added to the calculated value.
H
design
= (1.05 - 1.10) H
calculated
Horizontal Slurry Pumps hard metal or with rubber, polyurethane or
similar lining will be selected for the higher wear applications,
depending on the material to be handle.
Non froth slurry must be selected such that the maximum flow
including the fluctuation does not exceed 75 % of the flow range
indicated in the pump curve.
For frothy slurries, the maximum flow will not exceeds 60 % of the
flow range indicated in the pump catalog, without considered the
incorporate air slurry
Project C-560
Design Criteria 000-GD-P-006
Piping Design Criteria
Rev. 2
Q:\Shared\R0534200\01_Eng_Doc\05_Pip\01_Design_Criteria\02_Int_App\000-GD-P-006 Piping Design Criteria\560-000-GD-P-
006_2.doc
Page 37 of 43
For grinding circuit pumps, the Warman Method shall be used to
calculate the corrected TDH for effect of solid.
The power will be calculated with the TDH without being corrected for
the solid effect
For flotation circuit slurry pumps, a froth factor shall be applied in
accordance with the Process Design Criteria 000-GD-T-001
The motor nominal power shall be the minimum calculated brake
power increased by 20 %
The Tip speed of the impeller shall not be higher than 30 m/s to avoid
wearing out the impeller and casing.
23.5.4 Design Criteria For Frothy Slurry Pumping
The hydraulic calculation considerations indicated in 23.5.3 are valid
and in addition, the following considerations are to be included:
- For new horizontal froth pumps of Warman will be used the
procedure indicated in Warman Technical Bulletin N 28
(attached).
- For others pumps used the Weir Slurry Pumping Manual,
Appendix 1 Diagrams for Use in Slurry Pumping (attached).
23.5.5 Design Criteria For Water Flow
23.5.5.1 Flow Type
All water systems shall be designed for pressurized flow- i.e. line
flowing full, including gravity lines.
23.5.5.2 Flow Velocity
The flow velocity shall provide for the pressure drop rates set out in
Annex A.
Where the pipeline length is significant and pressure drop and
resultant energy cost is important, then the optimal economical line
size shall be determined.
Project C-560
Design Criteria 000-GD-P-006
Piping Design Criteria
Rev. 2
Q:\Shared\R0534200\01_Eng_Doc\05_Pip\01_Design_Criteria\02_Int_App\000-GD-P-006 Piping Design Criteria\560-000-GD-P-
006_2.doc
Page 38 of 43
23.5.5.3 Pressure Drop
For water flow, the pressure drop will be calculated in accordance with
the Darcy formula:
Darcy Colebrook Formula
|
.
|
\
|
|
|
.
|
\
|
=
D
L
g
V
f H
c
2
2
Or
|
.
|
\
|
|
|
.
|
\
|
=
D
L
g
V
f H
c
2
' 4
2
Hc = pressure drop in fluid column. (m)
f = Friction factor of Colebrook
f = Friction factor of Churchill
f = 4f
L = Total length in m (pipe length + fittings equivalent length,
Le/D = K/f).
V = flow velocity (m/s).
g = gravity acceleration (m/s
2
)
D = internal diameter (m).
To calculate the friction factor (f or f) the Colebrook or Churchill
formula shall be applied:
Colebrook Formula
+
|
.
|
\
|
=
f
D
e
f Re
51 . 2
7 . 3
log 2
1
Churchill Formula
|
.
|
\
|
+
|
.
|
\
|
=
9 . 0
Re
7 27 . 0
log 4
'
1
D
e
f
R
e
= Reynolds number = VD/
R
e
> 4000
D = internal diameter (m).
V = flow velocity (m/s).
Kinematics viscosity (m/s)
c = absolute roughness of pipe or launder wall
For new steel pipe, pH neutral water or slightly acidic water:
roughness ( c ) = 0.1 mm
Project C-560
Design Criteria 000-GD-P-006
Piping Design Criteria
Rev. 2
Q:\Shared\R0534200\01_Eng_Doc\05_Pip\01_Design_Criteria\02_Int_App\000-GD-P-006 Piping Design Criteria\560-000-GD-P-
006_2.doc
Page 39 of 43
For new steel pipe, alkaline water: roughness ( c ) = 0.1 mm plus an
increase of 0.2 mm per year. Calculation Sheet shall be verified for a
maximum roughness of ( c ) = 5 mm.
For HDPE pipe: roughness ( c ) = 0.02 mm
All values of total friction drop shall have a design margin of 5% - 10%
added to the calculated value.
The static head shall be calculated from the pump centerline to the
highest point of the discharge line.
23.5.5 Gas Conduction
The pipe sizing for gases will be made in accordance with attachment
SD-P-117 General Allowable Velocities. The design flow shall be 1.5
of the nominal flow (balance flow).
For pressure drop estimation in gases lines, the Darcy-Colebrook
formula shall be used.
23.5.6 Hydraulic Oil Piping System
The pressure drops will be calculated per Darcy-Colebrook method,
with a design factor of 20% added.
The safety factors in relation to the working pressure, design pressure
and allowable pressure will be according to the Vendor's
recommendations, the same as the maximum flow velocity.
23.5.7 Hydraulic Transient Design
Transient pressures resulting in sudden changes of pressure in a
pipeline shall be analyzed with the software AFT impulse.
Depending on results of the analysis, where necessary, surge devices
shall be incorporated or pipeline redesign shall be undertaken
23.5.8 Transfer Boxes Sizing
Transfer boxes must be sizing so as to avoid slurry overflow and
spattering. For this purpose, the following conditions must be
simultaneously applied to any flow range defined by balance (See
figure N 2)
Project C-560
Design Criteria 000-GD-P-006
Piping Design Criteria
Rev. 2
Q:\Shared\R0534200\01_Eng_Doc\05_Pip\01_Design_Criteria\02_Int_App\000-GD-P-006 Piping Design Criteria\560-000-GD-P-
006_2.doc
Page 40 of 43
H1 The vertical clearance of the outlet must at least 20% more than
the critical Bernoulli (Bc) head defined for design flow
R The freeboard or vertical clearance in the transfer box must be
of at least 2.0 velocity heads (V
2
/2g) measured with respect to the
maximum volume of pulp velocity of incoming pulp
De The depth of the box under the floor of the discharge section
must be considered in order to have a buffering cushion for the slurry.
The minimum depth of this cushion will be (H/3) 0.5
H2 The vertical distance between the bottoms of the inlet launder
and the static head in the transfer box must be at least 0.5 m
Lc The length of the transfer box Lc must be equal or more than 2
times the horizontal distance Lp of the trajectory of the feed slurry into
the box (maximum flow)
Lp
H
H1 =1.2 Bc
De= (H/3)
0.5
Bc
g
v
x R
2
2
2
=
H2 0, 5 m
Fig N 2
H
N
D
L 5D
Lc 2 Lp
Project C-560
Design Criteria 000-GD-P-006
Piping Design Criteria
Rev. 2
Q:\Shared\R0534200\01_Eng_Doc\05_Pip\01_Design_Criteria\02_Int_App\000-GD-P-006 Piping Design Criteria\560-000-GD-P-
006_2.doc
Page 41 of 43
L In case of the exit flow be conduit to a closed pipe, a vent will be
provided located no farther than 5 diameters from the outlet of the
transfer box. The height of the vent will be equal to or greater than the
transfer box.
- The discharge piece must ensure that the flow runs in the flume,
accelerating towards normal height conditions. If possible normal
conditions must be reached at the ends of the transitions piece.
- According to flow characteristic and design feasibility, transfer
boxes must be designed with a stone bed or buffering cushion, bottom
drainage (quick opening and full flow) and lids to prevent the froth
from overflowing).
- Expansions nozzles will be considered in the design of some
inlets to the transfer boxes in order to reduce drop speed
23.5.9 Head losses in dart valves
The head losses in dart valves will be estimated according to the
following formula:
g
CS Q H
2
) / (
2
=
Where:
H = Loss of head in the dart valves (m)
Q = Slurry flow m3/s
S = Orifice cross section (m
2
)
C = Coefficient of discharge flow, for dart valve C = 0.61
23.5.10 Pump boxes sizing
Adequate transfer time retention will be provided in all sumps to
accommodate fluctuations in the sump feed and to allow proper level
control.
Process sumps will be sized in accordance with process requirements
in terms of retention of slurry at design flow rates unless specifically
stated otherwise.
Project C-560
Design Criteria 000-GD-P-006
Piping Design Criteria
Rev. 2
Q:\Shared\R0534200\01_Eng_Doc\05_Pip\01_Design_Criteria\02_Int_App\000-GD-P-006 Piping Design Criteria\560-000-GD-P-
006_2.doc
Page 42 of 43
Sumps handling flotation froth will be oversized where required
handling pulp volume based on froth factors given in the Process
Design Criteria.
Retention capacity will be based on the volume of the sump between
300 mm above the top of the sump suction nozzle and the invert
elevation of the sump overflow weir.
Above grade concrete and steel sumps for horizontal slurry pumps
handling fine materials (minus 6 mm) will be rectangular in plan, with
vertical sides and sloped back wall. Back wall slope will be 50
degrees from the horizontal unless noted otherwise on the design
drawings.
Freeboard will be not less than 300 mm above the liquid level at the
maximum overflow conditions. The overflow will be not less than one
pipe size larger than the pump suction opening.
Process sumps with capacities of 2.0 cubic meters or larger will be
designed with overflow consisting of a weir and collecting box with
bottom outlet.
Quick opening wedge type drain caps will be used on all above
ground sump.
Drains will be designed to open easily and leak-proof.
Sumps handling coarse (+ 6 mm) material will be constructed of cast
or embedded concrete with vertical and or slopping walls. Sump
handling fine materials and concentrate will be made of either carbon
steel plate or concrete.
Connections for instrumentation will be as short as possible to prevent
building of solid. Flanged bossed will be welded directly to the sump
walls (or embedded into the walls of concrete sumps). The openings
in the grating will be no larger than the top size of materials that can
be handed by pump.
All sumps, other than sample transfer sump, either floor or above
grade, will include provision for injecting process water in the bottom
to remove settled solid and in the top to adjust solid concentration.
The sump design and construction must be in accordance with the
civil/structural design criteria.
Project C-560
Design Criteria 000-GD-P-006
Piping Design Criteria
Rev. 2
Q:\Shared\R0534200\01_Eng_Doc\05_Pip\01_Design_Criteria\02_Int_App\000-GD-P-006 Piping Design Criteria\560-000-GD-P-
006_2.doc
Page 43 of 43
23.5.11 Junction Boxes, Sampling Boxes And Distributor
Junction boxes with step-downs will be used for direction changes in
open launders where the change is greater than 45 degrees and is
abrupt or of short radius. They will also be used to merge launders
flows. A distributor will be used where it is necessary to divide a
process slurry stream into two or more streams of specified
proportions having the same solid concentration, sizing and
composition as the original stream. A splitter may be used where it is
necessary to divide a flow stream in two provided that control of the
flow rates and elimination of segregation is not important. As flow
splitters are subject to high wear, due precautions will be taken to
reduce wear in these areas.
Junction boxes will be sized with enough volume to absorb and
dissipate excessive kinetic energy in the streams while maintaining
most of the slurry solid in suspension.
Junction boxes, sampling boxes and distributors handling coarse
material (+ 6 mm) will be made of elastomer-lined carbon steel.
Elastomer will be a minimum 13 mm thick. Junction boxes and
distributors handling reground concentrates will be made of carbon
steel, without lining
24 ATTACHMENTS
The following documents are part of this specification:
FIG N 1 Chart of McElvain & Cave
FIG N 3 Diagram for ER- HR
Bulletin N 28
SD-P-115, Normal Suction and Discharge Velocities for Design
SD-P-117, General Allowable Velocities
Aker Solutions General Specifications References
000-OT-M-001 Appendix A, Standard Technical and Site Data
000-GD-P-007, General Specification, Piping Material Classes.
000-GC-P-013, Piping and Tank Insulation
000-GD-S-002, Civil, Structural and Architectural Design Criteria
000-GD-T-001, Process Design Criteria