The Design of Pipe Systems

and Pumps

An introductory guide to piping and pumps systems for

chemical engineers.
Example:
1.54
bara
6.5 m

1.01
bara
4.2 m

14 m
 Example:
Fluid Characteristic:
Liquid pumped: Crude oil
Pumping Temp.: 40oC
Density at PT: 805 kg/m3
Specific gravity: 0.805
Viscosity at PT: 3.2 cP
Normal flow Q at PT: 189 m3/hr.
Suction Line:
Gate Valve: 0.2 bar Delta P
Suction line length: 20 m
Elbow 90o Curved (L/D)eq = 17
Pipe Diameter : 102.3 mm
Discharge Line:
Gate Valve: 0.2 bar Delta P
check Valve: 0.2 bar Delta P
control valve: 0.15 bar Delta P
Heat Exchanger: 0.2 bar Delta P
Discharge line length: 550 m
Pipe Diameter: 102.3 mm
 Suction Pressure (bara)
1) Minimum Operation Pressure (bara) = 1.54 bara
1.54
bara
1.54 ×10.197
Minimum Operation Pressure (m) = = 19.5 m
0.805

6.5 m
2) Static Head at low level (m) = 4.20 m

Static Head at low level (bar) = 4.20 X 0.805 X 0.0981

4.2 m
= 0.33 bar
 Suction Pressure (bara)
3) Suction Line Pressure Drop:
𝐹𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 189 1 1.54
Velocity = = 𝑋 = 6.39 m/s bara
𝐴𝑟𝑒𝑎 𝜋 0.1023 2 /4 3600

6.5 m
𝐷𝑒𝑛𝑠𝑖𝑡𝑦 ×𝑉𝑒𝑙𝑜𝑐𝑖𝑡𝑦 ×𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟
Re =
𝑉𝑖𝑠𝑐𝑜𝑠𝑖𝑡𝑦

805 ×6.39 ×0.1023

= 3.2 𝑠 = 164445 > 2100 Turbulent Flow

4.2 m
(𝑁. )
1000 𝑚2

0.316 0.316
F= = = 0.0156
𝑅𝑒 0.25 (1644450.25 )

𝐿 𝑉2 20+17𝑋0.1023 6.392
Hf = f X ( ) X = 0.0156X ( ) X = 6.9 m
𝐷 2𝑔 0.1023 2𝑋9.81
= 6.9 X 0.805 X 0.0981 = 0.545 bar
 Suction Pressure (bara)

1.54
Total Delta P = Line Pressure Drop + Equipment Pressure bara
Drop = 0.545 +0.2 = 0.75 bar

6.5 m
Pump Suction Pressure = 1.54 + 0.33 – 0.75 = 1.12 bara

4.2 m
 NPSH (m)

NPSH = Head level – Line Pressure Drop + Min operating 1.54

bara
Pressure – Vapour Pressure

6.5 m
0.75 ×10.197
= 4.20 – ( ) + 19.5 = 14.2 m
0.805

4.2 m
 Discharge Pressure (bara)
1) Maximum Operating Pressure = 1.01 bara

2) Static Head at High Level = 14 m X 0.805 X 0.0981 = 1.1055 bar

𝐿 𝑉2
3) Line Pressure drop = Hf = f X ( ) X
𝐷 2𝑔
550 6.392
= 0.0156 X ( )X = 174 m =174 X 0.805 X 0.0981 = 13.78 bar
0.1023 2𝑋9.81

4) Total Delta P = 13.78+0.2+0.2+0.2+0.15 = 14.53 bar

1.01
5) Pump Discharge Pressure = 14.53 + 1.01 +1.1055 = 16.6 bara bara

14 m
Differential Pressure
• Differential Pressure:
DP = Discharge Pressure - Suction Pressure
= 16.6 – 1.12 = 15.6 bar
Power
𝐹𝑙𝑜𝑤 𝑟𝑎𝑡𝑒𝑋𝐷𝑃
• Power =
36

189𝑋15.6
= = 81.9 kW
36
Optimum Pipe Size
• Several equations and monographs are available to estimate
the optimum pipe diameter.
• One suction equation derived for carbon steel pipe and
turbulent flow is:

0.53 -0.37
dop = 293 X G X density
Optimum Pipe Size

• Example: Estimate the optimum pipe diameter for a flow of

dry chorine gas of 10,000 kg/hr at 6 atm.a and 20oC through
carbon steel pipe, optimum pipe diameter:
0.53 -0.37
dop = 293 X G X density
G = 10000 kg/hr = 2.7778 kg/s
𝑃𝑀 6 𝑋 17 3
Density = = = 17. 71 kg/m
𝑅𝑇 0.08205 𝑋 ( 273+20)
0.53 -0.37
dop = 293 X (2.7778) X (17.71) = 173.885 mm = 8 inch.
Standard Pipe:
𝑃𝑠𝑡 𝑋 1000
• Schedule Number, Sch =
𝜎𝑠
Where,
Pst = Safe working pressure
𝜎s = Safe allowable pressure
For example, the schedule number of ordinary steel pipe
having an allowable stress of 10000 psi for use at working
pressure 350 psig is:
Sch. = 1000 X 350 / 10000 = 35 (Sch.40).
Pumps Operation
What is pump cavitation?

• Simply defined, cavitation is the formation of bubbles or

cavities in liquid, developed in areas of relatively low
pressure around an impeller. The imploding or collapsing of
these bubbles trigger intense shockwaves inside the pump,
causing significant damage to the impeller and/or the pump
housing.
 What is pump cavitation?
If left untreated, pump cavitation can cause:
• Failure of pump housing
• Destruction of impeller
• Excessive vibration - leading to premature seal and bearing failure
• Higher than necessary power consumption
• Decreased flow and/or pressure

There are two types of pump cavitation: suction and discharge.

 Suction Cavitation
• When a pump is under low pressure or high vacuum conditions, suction
cavitation occurs. The pump is being "starved" or is not receiving enough
flow. When this happens, bubbles or cavities will form at the eye of the
impeller. As the bubbles carry over to the discharge side of the pump, the
fluid conditions change, compressing the bubble into liquid and causing it
to implode against the face of the impeller.

• An impeller that has fallen victim to suction cavitation will have large
chunks or very small bits of material missing, causing it to look like a
sponge.
 Suction Cavitation
Possible causes of suction cavitation:

• Clogged filters or strainers

• Blockage in the pipe
• Pump is running too far right on the pump curve
• Poor piping design
• Poor suction conditions (NPSH requirements)
Discharge Cavitation
• When a pump's discharge pressure is extremely high, or
runs at less than 10% of its best efficiency point (BEP),
discharge cavitation occurs. The high discharge pressure
makes it difficult for the fluid to flow out of the pump, so it
circulates inside the pump. Liquid flows between the
impeller and the housing at very high velocity, causing a
vacuum at the housing wall and the formation of bubbles.
Discharge Cavitation
Possible causes of discharge cavitation:

• Blockage in the pipe on discharge side

• Clogged filters or strainers

• Running too far left on the pump curve

• Poor piping design

 Cavitation Prevention
If your pumps are experiencing cavitation, check these things to troubleshoot the
problem on your own:

1) Check filters and strainers - clogs on the suction, or discharge side can cause
an imbalance of pressure inside the pump

2) Reference the pump's curve - Use a pressure gauge and/or a flowmeter to

understand where your pump is operating on the curve. Make sure it is running
at its best efficiency point

3) Re-evaluate pipe design - Ensure the path the liquid takes to get to and from
your pump is ideal for the pump's operating conditions
Excel Functions
‫االرتفاع‬ ‫الحجم‬
0 2834
1 8163
2 13492
3 18821
4 24150
5 29478
6 34807
7 40136
8 45465
9 50794
 Excel Functions

=FORECAST(NewX;OFFSET(KnownY;MATCH(NewX;KnownX;1)-
1;0;2);OFFSET(KnownX;MATCH(NewX;KnownX;1)-1;0;2))
 Block Flow Diagram
• Rectangles in Block Flow Diagrams represents unit operations.
Blocks are connected by straight lines representing process
flow streams.
Block Flow Diagram
Process Flow Diagram
• Is a diagram commonly used in chemical and process
engineering to indicate the general flow of plant processes
and equipment. The PFD displays the relationship between
major equipment of a plant facility and does not show
minor details such as piping details and designations.
Another commonly used term for a PFD is a flowsheet.
Process Flow Diagram
Piping and instrumentation diagram

• A piping and instrumentation diagram (P&ID) is a detailed diagram

in the process industry which shows the piping and vessels in the
process flow, together with the instrumentation and control devices.

• Superordinate to the piping and instrumentation flowsheet is the

process flow diagram (PFD) which indicates the more general flow of
plant processes and equipment and relationship between major
equipment of a plant facility.
Piping and instrumentation diagram

• A piping and instrumentation diagram (P&ID) is defined by

the Institute of Instrumentation and Control as follows:

A diagram which shows the interconnection of process

equipment and the instrumentation used to control the
process. In the process industry, a standard set of
symbols is used to prepare drawings of processes.
Piping and instrumentation diagram

• Process piping, sizes and identification, including:

1) Pipe classes or piping line numbers

2) Flow directions

3) Interconnections references

4) Permanent start-up, flush and bypass lines

 Piping and instrumentation diagram
• Mechanical equipment and process control instrumentation and designation
(names, numbers, unique tag identifiers), including:

1) Valves and their identifications (e.g. isolation, shutoff, relief and safety valves)
2) Control inputs and outputs (sensors and final elements, interlocks)
3) Miscellanea - vents, drains, flanges, special fittings, sampling lines, reducers
and increasers
4) Interfaces for class changes
5) Computer control system
6) Identification of components and subsystems delivered by others
 Piping and instrumentation Software

1) AutoCAD P & ID
2) Smart Plant
3) Microsoft Visio
4) Plant 4D
5) …….