PIPINGANDPUMPS

1. TYPESOFPUMPS
Pumps are in general classified as Centrifugal Pumps (Rotodynamic pumps) and Positive
DisplacementPumps.

CentrifugalPumps(Rotodynamicpumps)

Thecentrifugalorrotodynamicpumpproduceaheadandaflowbyincreasingthevelocity
of the liquid through the machine with the help of a rotating vane impeller.Centrifugal
pumpsincluderadial,axialandmixedflowunits.

Centrifugalpumpscanfurtherbeclassifiedas

Endsuctionpumps
Inlinepumps
Doublesuctionpumps
Verticalmultistagepumps
Horizontalmultistagepumps
Submersiblepumps
Selfprimingpumps
Axialflowpumps
Regenerativepumps

PositiveDisplacementPumps
Thepositive displacement pumpoperates by alternating of filling a cavity and then
displacing a given volume of liquid. The positive displacement pump delivers a constant
volumeofliquidforeachcycleagainstvaryingdischargepressureorhead.

Thepositivedisplacementpumpcanbeclassifiedas:

Reciprocatingpumps
Powerpumps
Steampumps
Rotarypumps
SelectingbetweenCentrifugalorPositiveDisplacementPumps
Selecting between aCentrifugal Pumpand aPositive Displacement Pumpis not always
straightforward.

FlowRateandPressureHead

o TheCentrifugalPumphasvaryingflowdependingonthesystempressureorhead.
o ThePositiveDisplacementPumphasmoreorlessaconstantflowregardlessofthe
system pressure or head. Positive Displacement pumps generally gives more
pressurethanCentrifugalPumps.

CapacityandViscosity

o IntheCentrifugalPumptheflowisreducedwhentheviscosityisincreased.
o InthePositiveDisplacementPumptheflowisincreasedwhenviscosityisincreased.

MechanicalEfficiency

o Changingthesystempressureorheadhaslittleornoeffectontheflowrateinthe
PositiveDisplacementPump
o Changingthesystempressureorheadhasadramaticeffectontheflowrateinthe
CentrifugalPump

NetPositiveSuctionHead(NPSH)

o InaCentrifugalPump,NPSHvariesasafunctionofflowdeterminedbypressure
o In aPositive Displacement Pump, NPSH varies as a function of flow determined by
speed.ReducingthespeedofthePositiveDisplacementPump,reducestheNPSH.

2. PUMPLOCATIONS

Hot Water System: Boilers to be on the suction side of pumps, since the temperature of
supplysideishigherthanreturnsideandalsoinclosedloopi.e.theclosedloopcircuithas
no need for consideration of static heads for pump selection because of a balance or
cancellationofstaticheadsbetweensupplyandreturn.Sopumpstodrawthroughboilers.

Chilled Water System: Chillers to be on the discharge side of the pumps, since the
temperature of return side is higher than supply side and also closed loop i.e. the closed
loopcircuithasnoneedforconsiderationofstaticheadsforpumpselectionbecauseofa
balance or cancellation of static heads between supply and return. So pumps to pump
throughchiller.

CondenserWaterSystem:Coolingtowertobeonthesuctionsideofpumps.Eventhough
the return side temperature is higher than supply side, this is because condenser water
pumps must over come pressure drop through chillers condenser, the condenser water
pipes,elbows,valves,andliftthewaterfrombasintothetopofcoolingtower(Staticlift)
i.e. because of open loop. So open static becomes an important consideration for pump
selection.

3. PUMPNETPOSITIVESUCTIONHEAD(NPSH)ANDPUMPCAVITATION
PUMPNETPOSITIVESUCTIONHEAD(NPSH):
The net positive suction head (NPSH) is an expression of minimum suction condition
requiredtopreventcavitation,reducedefficiencyinapump.
NPSHcanbedefinedastwoparts:
NPSHAvailable(NPSHA):Theabsolutepressureatthesuctionportofthepump.Itis
dependentonthepipingsystemdesignaswellastheactuallocationofpumpinthat
systemandmustbecalculated.
NPSHRequired(NPSHR):Theminimumpressurerequiredatthesuctionportofthe
pumptokeepthepumpfromcavitation.Itisdependentonthepumpandmustbe
providedbythepumpmanufacturer.
NPSHA mustbegreaterthanNPSHRforthepumpsystemtooperatewithoutcavitation.I.e.
youmusthavemoresuctionsidepressureavailablethanthepumprequires.

CalculatingNPSHA
Its critical to get the NPSHR value from the pump manufacturer and to ensure that NPSHA
pressurewillbeadequate.

NPSHA=HAHZ HF+HV HVP

Where,
1. HATheabsolutepressureonthesurfaceoftheliquidinthesupplytank.(Typically
atmosphericpressure(Opentanks),butcanbedifferentforclosedtanks)
2. HZTheverticaldistancebetweenthesurfaceoftheliquidinthesupplytankandthe
centrelineofthepump.(Canbepositivewhenliquidlevelisabovethecenterlineof
thepumpcalledstatichead.Canbenegativewhenliquidlevelisbelowthecentre
lineofthepumpcalledsuctionlift)
3. HF - Frictionlossesinthesuctionpiping.
4. HV Velocity head at the pump suction port. (Often not included as its normally
quitesmall)
5. HVP Absolute vapor pressure of the liquid at the pumping temperature. (Must be
subtracted in the end to make sure that the inlet pressure stays above the vapor
pressure)

PUMPCAVITATION:
Pump cavitation occurs when the pressure in the pump inlet drops below the vapor
pressureoftheliquid.Vaporbubblesformattheinletofthepumpandaremovedtothe
discharge of the pump where they collapse, often taking small pieces of the pump with
them.Cavitationisoftencharacterizedby:
Loudnoisesinthepump.
Lossofcapacity.
Pittingdamagetopartsasmaterialisremovedbythecollapsingbubbles.

4. PUMPSYSTEMCURVEANDPUMPPERFORMANCECURVE
PUMPSYSTEMCURVE:
The impact of flow in any piping system is very predictable and can be graphically
representedasasystemcurve.Agraphicalrepresentationofthehydrauliccharacteristicsof
a piping system. Laying the pump curve over the system curve gives the point at which a
particularpumpwilloperateinthesystemforwhichcurveisplotted.
The system head visualized in the System Curve is a function of the elevation the static
headinthesystem,andthemajorandminorlossesandcanbeexpressedas:

H=dH+HL
Where,
H=Systemhead
dH=H2H1(Staticheadi.e.differencebetweeninletandoutletofthesystem)
HL=Headloss
Agenericexpressionofheadlossis:

Where, HL=K*Q2

Q=flowrate
K =constant describing the total system characteristics (including allmajor and minor
losses)

IncreasingtheconstantKValuesbyclosingsomevalves,reducingthepipesizeorsimilar
willincreasetheheadlossandmovethesystemcurveupwards.Thestartingpointforthe
curveatnoflow,willbethesame.

Example:

PUMPPERFORMANCECURVE:
A graphical representation of a pump performance characteristics given by the
manufacturer. Each pump has a definite capacity curve for a given impeller diameter and
Speed. The pump curve describes the relation between flow rate and head for the actual
pump.Otherimportantinformationforproperpumpselectionisalsoincludedefficiency
curves,NPSHcurve,pumpcurvesforseveralimpellerdiametersanddifferentspeeds,and
powerconsumption

Increasingtheimpellerdiameterorspeedincreasestheheadandflowratecapacityand
thepumpcurvemovesupwards.
Theoperatingpointiswherethesystemcurveandtheactualpumpcurveintersect.

BestEfficiencyPoint(BEP)
Thebestoperatingconditionswillingeneralbeclosetothebestefficiencypoint.
Theheadcapacitycanbeincreasedbyconnectingtwoormorepumpsinseries,ortheflow
ratecapacitycanbeincreasedbyconnectingtwoormorepumpsinparallel.
PumpsinSerialHeadsAdded
Whentwo(ormore)pumpsarearrangedinserial,theirresultingpumpperformancecurve
isobtainedbyaddingtheirheadsatsameflowrateasindicatedinthefigurebelow.

Centrifugalpumpinseriesareusedtoovercomelargersystemheadlossthanonepumpcan
handlealone.Fortwoidenticalpumpsinseriestheheadwillbetwicetheheadofasingle
pumpatthesameflowrate.Withconstantflowratethecombinedheadmovesfrom1to2.
Inpracticethecombinedheadandflowratedmovedalongthesystemcurveto3.
If one of the pumps stops, the operation point moves along the system resistance curve
frompoint1topoint2headandflowratearedecreased.
PumpsinParallelFlowRateAdded
When two or more pumps are arranged in parallel their resulting performance curve is
obtainedbyaddingtheirflowratesatthesameheadasindicatedinthefigurebelow.

Centrifugalpumpsinparallelareusedtoovercomelargervolumeflowsthanonepumpcan
handle alone. For two identical pumps in parallel the flow rate will double (moving from
point1to2)comparedtoasinglepumpifheadiskeptconstant.Inpracticethecombined
headandvolumeflowmovesalongthesystemcurveasindicatedfrom1to3.
Ifoneofthepumpsinparallelorseriesstops,theoperationpointmovesalongthesystem
resistancecurvefrompoint3topoint1theheadandflowratearedecreased.

Example:
IfthedesignpointforagivenpipingsystemwereDischarge(Q)=600gpmandHead(H)=
270ft,thefollowingpumpselectioncriteriawouldapply:
1.SinglepumpsystemQ=600gpm,H=270ft.
2.ParallelpumpsystemQ=300gpm,H=270ft.foreachofthetwopumps
3.SeriespumpsystemQ=600gpm,H=135ft.foreachofthetwopumps

5. VALVES

Avalveisamechanismforregulatingtheflowofliquidsandgases,anditisoftenfoundin
pump systems. Valves manage material flow by opening, narrowing, or closing a pipe
passage.

Generallyusedpumpsuctionsidevalvesare
CheckValves.
PlugValves.
Strainers.

Generallyusedpumpdischargesidevalvesare
ShutoffValves.
BallValves.
ButterflyValves.
CheckValves.
TripledutyValves.


6. PIPESIZING

HVACpipingistypicallysizedaccordingtorulesofthumbsuchasmaximumfrictionrateor
velocity,oracombinationofthetwo,whichisfrictionrateislimitedto4ftper100ftand
velocityislimitedto10fps.

Pipesizingisafunctionof:
Locationofpipeinthesystem.
Firstcostsofinstalledsystemincludingpiping,fittings,valves,etc.
Erosionconsiderations.(Highvelocitiescancontributetohasteningofpipewall
deterioration)
Noiseconsiderations.(Highvelocitiesandturbulencecancausenoiseproblemsin
occupiedareas)
BudgetConstraints.

7. PIPEFRICTIONLOSS

Flow of fluid through a pipe is resisted by viscous shear stresses within the fluid and the
turbulencethatoccursalongtheinternalpipewall,whichisdependentontheroughnessof
the pipe material.

This resistance is termed pipe friction and is usually measured in feet head of the fluid,
whichisalsoreferredastheheadlossinpipe.
Overallheadlossinapipeisaffectedbyanumberoffactorswhichincludetheviscosityof
thefluid,thesizeoftheinternalpipediameter,theinternalroughnessoftheinnersurface
ofthepipe,thechangeinelevationbetweentheendsofthepipeandthelengthofthepipe
alongwhichthefluidtravels.
Valvesandfittingsonapipealsocontributetotheoverallheadlossthatoccurs,however
thesemustbecalculatedseparatelytothepipewallfrictionloss.

CALCULATIONSPIPEFRICTIONLOSS:
DarcyWeisbachFormula

HF=f(L/D)x(V^2/2g)
Where,
HF=headloss(ft.)
f=frictionfactor
L=Lengthofpipework(ft.)
D=innerdiameterofpipework(ft.)
V=velocityoffluid(ft./s)
g=accelerationduetogravity(ft./s)

TheMoodyChartfinallyprovidedamethodoffindinganaccuratefrictionfactor.

HazenWilliamsFormula

HF=0.002083xLx(100/C)^1.85x(gpm^1.85/d^4.8655)

Where,
HF=headloss(ft.)
L=Lengthofpipework(ft.)
C=frictioncoefficient
gpm=gallonsperminute
d=insidediameterofpipework(in)

Note:TheempiricalnatureofthefrictionfactorCmeansthattheHazenWilliamsformulais
notsuitableforaccuratepredictionofheadloss.Thefrictionlossresultsareonlyvalidfor
fluidswithakinematicviscosityof1.13centistokes,wherethevelocityofflowislessthan
10feetpersec,andwherethepipediameterhasasizegreaterthan2inches.
PipeFittingsLossCalculationswithKFactors
Pipefittings,valvesandbendsusuallyhavesomeassociatedKfactororlocallosscoefficient,
which allows the calculation of the pressure loss through the fitting for a particular fluid
flowingataspecifiedvelocity.Manufacturersofpipeworkfittingsandvalvesoftenpublish
afitting'sassociated'K'factor.
Fluidheadlossthroughafittingcanbecalculatedbythefollowingequation:

h=KxV/2g
where
h=pressurelossintermsoffluidhead,i.e.fluidheadloss.
K=manufacturer'spublished'K'factorforthefitting.
V=velocityoffluid.
g=accelerationduetogravity.

8. PIPINGTHERMALEXPANSION
Pipesexpandswhenheatedandcontractswhencooled.Theexpansionofthepipescanbe
expressedwiththeexpansionformula
Thetemperatureexpansionofpipesdependsonthestartandfinaltemperatureofthepipe
andtheexpansioncoefficientofthepipingmaterialattheactualtemperature.Thegeneral
expansionformulacanbeexpressedas:

dl=Ldt
Where,
dl=expansion(Inches)
L=lengthofpipe(Inches)
dt=temperaturedifference(F)
=linearexpansioncoefficient(in/inF)
9. PIPINGMATERIALS

All piping systems shall be designed and sized in accordance with ASHRAE. Materials
acceptable for piping systems are black steel, stainless steel and copper. No PVC or other
typesofplasticpipearepermitted.

Steelisnormallyalessexpensivematerialandismorepopularforsizesover1inch.
Copperisexpensivematerialbutitisverypopularat1inchandnarrower,duetoits
easeofinstallation.

STANDARDPIPING
USE
MATERIAL

Chilledwaterupto300mm(12in)dia.
Condenserwaterupto300mm(12in)dia.
ASTMSchedule40
Hotwater.
Naturalgas,fueloil.

Chilledwaterover300mm(12in)dia.
ASTMSchedule30
Condenserwaterover300mm(12in)dia.

ASTMSchedule80 Steamcondensate

Chilledwaterupto102mm(4in)dia.
Condenserwaterupto102mm(4in)dia.
CopperTubing
Domesticwater.
Refrigeration.
10.PIPINGINSULATION

PipeInsulationisthermaloracousticinsulationusedonpipework.

BenefitsofPipeinsulation:

ReduceHeatLoss,Reduceenergyprices.
FireProtectionandProtectionagainsthotpipes.
PreventCondensationandpipesfromfreezing.
Protectionfromcorrosion.
SoundReductionandAcousticProtection.

Pipeinsulationmaterialscomeinalargevarietyofforms,butmostmaterialsfallintooneof
thefollowingcategories.

Mineralwool.
Glasswool.
Flexibleelastomericfoams.
Rigidfoam.
Polyethylene.
CellularGlass.
Aerogel