Professional Documents
Culture Documents
Equipment Design
(PED)
CHEN90012, 2017
Volume 1
Chapter 1 Introduction 1
Assessment
Assessment will be based on
Tutes
Go to your assigned tutorial session, one of the following.
Monday, 1 or 2:15 PM
Tuesday, 4:15 or 5:15 PM
Wednesday, 9 or 10 AM
Thursday, 10 AM
Attendance at all lectures and one tute session each week is
mandatory
Office Hours: Thursday 12 -1 or by appointment.
Post questions about assignment on LMS discussion board
Chapter 1 Introduction 3
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TEXTS: The required text for this subject are the Lecture Notes
compiled by Franks. They are available on LMS.
Lecture Notes produced by Dr. Teresa Pong prior to 2006, are available
on LMS. These notes contain additional information which may be
needed for your Design Project in Semester 2. Please down load them
and save them for reference.
Additional texts used in compiling these notes will need to be consulted
from time to time including:
Couper, J.R., Penney, W. R., Fair, J.R., Walas, S. M., Chemical
Process Equipment, Selection and Design, 2nd Edition, Elsevier, 2005,
On line edition available from library through Knovel.
Perry’s Chemical Engineers Handbook (7th Edition), McGraw-Hill,
2004, On line edition available from library through Knovel.
Sinnott, R. K., Coulson and Richardson’s Chemical Engineering,
Volume 6, 3rd edition, 1999. Also volumes 2 and 1.
Sinnott, R. and Towler, G. Chemical Engineering Design, 5th Edition,
Elsevier, 2009
Chapter 1 Introduction 8
Also:
Australian Standards,
AS 1210 – Pressure Vessel, UniM ERC f 681.760410218 STAN - hard copy
AS 4041 – Pressure Piping, UniM ERC f 681.76041 PRES - hard copy
AS 1200 – Pressure Equipment
AS 1692 – Steel tanks for flammable and combustible liquids
AS 4343 – Pressure Equipment, Hazard Levels
AS 1940 – Handling and storage of flammable and combustible liquids
for e-version, go to supersearch – find data base – SAI global –
AS1210, AS1200, AS1692, AS4041 etc – view document
Additional TEXTS
Also used in compiling these notes
Treybal, R.E., ‘Mass Transfer Operations’. McGraw Hill, New York, 1980.
Zappe, R.W., ‘Valve Selection Handbook’, Gulf Publishing, Houston, 1991.
Pell, M., ‘Gas Fluidization’, New York, Elsevier, 1990.
Howard, J.R., ‘Fluidized Bed Technology, Principles and Applications’,
Adam Hilger, New York, 1989.
Chapter 1 Introduction 9
CHAPTER 1. INTRODUCTION TO
PROCESS EQUIPMENT DESIGN
Learning Objectives and Expectations
To be aware of the assessments, lecture and tute times and locations,
textbooks available and topics to be covered in this subject.
To be aware of the major types of process equipment.
To understand the importance of a culture of safety.
To understand environmental and economic considerations in design.
To be familiar with the data required for design.
Understand that there are rules of thumb for design which are guidelines.
Understand that good design requires experience and familiarity with
existing designs.
Brief introduction to process flow diagrams, sketches and engineering
drawings.
Understand the importance of designing using standard components
where possible.
Chapter 1 Introduction 10
CHAPTER 1. INTRODUCTION TO
PROCESS EQUIPMENT DESIGN
Chapter 1 Introduction 11
Chapter 1 Introduction 12
1. AIMS FOR THIS COURSE
Are to:
- Piping - Agitators
However, in a course like PED, it is impossible to deal with all these equipment in detail,
therefore a selection of the more important ones will be studied.
Chapter 1 Introduction 14
Pressure Vessels
Chapter 1 Introduction 15
Chapter 1 Introduction
Pressure Vessels 16
Non-Pressure Vessels
Storage Tanks
Chapter 1 Introduction 17
Non-Pressure Vessels
Storage Tanks
Chapter 1 Introduction 18
Pipework
Chapter 1 Introduction 19
Valves
Chapter 1 Introduction 20
Pumps
Chapter 1 Introduction 21
Pumps
Chapter 1 Introduction 22
Compressors
Chapter 1 Introduction 23
Heat Exchangers
Chapter 1 Introduction 24
Heat Exchangers
Chapter 1 Introduction 25
Distillation Column
Chapter 1 Introduction 26
Distillation Column
Chapter 1 Introduction 27
Operator
•Have to implement complex control Response
systems
•Rely on operator response Control System
Safety Onion
Chapter 1 Introduction 28
3. AIM OF THE PROCESS EQUIPMENT DESIGN
4. MONEY CONSIDERATION
After making sure that the equipment can be operated safely, it is
the duty of the engineer to:
- Make a profit for the firm
- Keep the project within budget
- Keep the costs to a minimum without sacrificing safety
Chapter 1 Introduction 29
- Process designer
Chapter 1 Introduction 31
7. A GOOD DESIGNER
- Must have a feel for that is right in the design
- Only experience can teach you what looks right
- Important that the design is appropriate for the task
- Typically greater accuracy of control than is necessary
- Capacity of pump or vessel is bigger than necessary
Chapter 1 Introduction 32
8. ENGINEERING DRAWINGS
- Not completely standardized
- Block diagrams
- PID
Chapter 1 Introduction 33
Block Diagram
Chapter 1 Introduction 34
Process Flow Sheet
Chapter 1 Introduction 35
PID
Chapter 1 Introduction 36
Equipment Sketches and Engineering Equipment Drawings
Equipment Sketches are less detailed drawings used to illustrate a
point when using words will be lengthy and ambiguous. Equipment
sketches may be used in the calculations section to help with
explanation of your design. Equipment sketches may be hand
drawn and not exactly to scale.
Chapter 1 Introduction 37
Chapter 1 Introduction 38
Equipment Sketches and Engineering Equipment Drawings
Chapter 1 Introduction 39
Chapter 1 Introduction 40
Equipment Sketches and Engineering Equipment Drawings
- Or parts and material for the equipment can be purchased so that the
equipment can be manufactured by the workshop
Chapter 1 Introduction 43
Chapter 1 Introduction 44
Chapter 1 Introduction 45
Chapter 1 Introduction 46
For pipes, they are supplied in standard sizes with some choices of wall
thickness, usually termed Schedule Number. You cannot buy anything
in between. See previous pages and more sheets on LMS.
For pumps, they are usually supplied with certain horsepower for the motor:
¼ HP ½ HP ¾ HP or in equivalent unit, kW
For flanges, there are Standard flanges, see next page and on LMS.
For the metal sheet or plate, you can only buy the sheet in the standard
dimensions and thickness, but not in between, see details on page 49.
Chapter 1 Introduction 47
Chapter 1 Introduction 48
Standard Steel Plate Sizes
Widths
Increments of 100 mm from 1200 mm to 3300 mm.
Thicknesses (mm)
5, 6, 8, 10, 12, 16, 20, 25, 28, 32, 36, 40, and so on.
Lengths
Increments of 200 mm from 4000 mm to 18000 mm.
Common sizes
Widths – 1800 mm, 2400 mm, and 3000 mm
Lengths – 6000 mm, and 9000 mm
Steel quality
- Pressure vessels from boiler and pressure vessel grades
- Non-pressure vessels from structural grades
Chapter 1 Introduction 49
Chapter 1 Introduction 50
12. THE JOB OF THE DESIGN ENGINEER
As the designer, you must design equipment that:
Chapter 1 Introduction 51
CHEN90012, Process Equipment Design, Tutorials, 2017.
Please attempt to solve the tutorial question during your assigned tutorial time. The Tutor will
work through the solutions during the second half of the Tutorial session. No marks are given
for the Tutorials.
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CHAPTER 2. PRESSURE VESSEL DESIGN
Learning Objectives and Expectations
To be familiar with pressure vessel components and features.
To understand the difference between pressure and non-pressure, fired
and un-fired vessels.
To understand the importance of regulations and standards in safe
design.
To be able to use AS1210 and related standards in pressure vessel
design.
To become familiar with rules of thumb regarding vessel design.
Understand why there is a minimum safe thickness.
To be able to determine the minimum design thickness.
To be able to design and specify the details of safe pressure vessels.
To be able to design pressure vessels in a economically efficient manner.
To be able to produce pressure vessel specification sheets and
equipment drawings.
Chapter 2 Pressure Vessels 1
1. VESSEL
A vessel is a container which holds a solid, a liquid or a gas, or a
combination of these.
Pressure
Vessels
At other times, energy and heat have to be added to the content of the
vessel. When heat transfer is involved, the vessel (pressure or
non-pressure) may be classified as:
A fired vessel is one where heat is added to the content of the vessel
by the application of fire, electrical power or similar high temperature means.
An unfired vessel is one where heat is added to the content of the vessel
by a stream of fluid at moderate temperatures.
This may be a tank containing liquid with a certain vapor pressure. The
absolute pressure of the vapor above the liquid is ~ atmospheric.
The present chapter will deal with pressure vessel only. The design of
non-pressure vessel will be discussed later.
AS 1210 1997
A
pressure
vessel
Not a
pressure
vessel
A
pressure
vessel
Not a
pressure
vessel
A simplified definition:
Most of the vessels built are thin walled. Thick walled vessels are used for
special applications only. We will consider thin walled vessels only here.
7. STATUTORY AUTHORITIES
All pressure vessels, for use in Australia, must meet the requirement of the
Statutory Authorities of the respective States of Australia before they can be
used.
c. Nozzles
- fluid inlet and outlet connections
d. Access holes
- manholes
- inspection holes
e. External support
nozzles
inlets
shell outlets
external supports
endcaps
Where pressure relief devices are used, the design pressure is often
assumed to be 5 percent to 10 percent above the operating pressure at
the most severe condition, but where wide surges in pressure and
temperature may occur, this margin may need to be increased. The
design pressure shall not be less than the set pressure of the lowest set
pressure-relief device. (more detail in chapter 6 about pressure relief
devices)
Chapter 2 Pressure Vessels 17
b. Select class of vessel (see AS 1210, Table 1.6 and 1.7, Clause 1.7)
Classification is made based on the design, construction, testing
and inspection requirements of the Code.
AS 1210, 1997
Table 1.6
Number in parentheses is
the welded joint efficiency
() if = 1, the structure is
not weakened by the
weld, if = 0.5, the
structure has half the
strength
- When a higher class is used, the welding efficiency goes up, the wall
thickness comes down. It may be cheaper to manufacture a Class 2
vessel than a Class 3 vessel.
- But the welding has to be done with better care to give a better quality
weld, and more testing procedures have to be followed and performed.
Hence the costs of testing must be considered and included.
Selection
- Start with a Class 3 vessel and apply the rules changing the class until
all the rules are passed.
PRESSURE VESSEL
General guidelines
Less than 4000 L – vertical tanks on legs: L/D ≈ 3 to 4
More than 4000 L – horizontal tanks on saddles : L/D ≈ 3 to 4
f. Select the end cap type – heads and closures of the cylindrical shells.
Economical considerations:
Non-pressure vessels – Flat Plates okay
Up to 10 bar (i.e. P < 1.0 MPa) use Torispherical heads
Above 15 bar (i.e. P > 1.5 MPa) use Ellipsoidal heads
Between 10–15 bar (i.e. 1.0–1.5 MPa) costs are about the same
The specific sizes of various typical end caps available are given in the
Australian Pressure Vessel Heads data sheet (see the following page)
Note, Ellipsoidal and Semi-Ellipsoidal refer to the same thing and can be used interchangeably.
Chapter 2 Pressure Vessels 28
SF
PD
tc t
2 f P 3.7.3 (1), AS1210
PD
t 3.7.4, AS1210
4 f P
1 D
2
where K 2
6 2h
D
K is a factor depending on the proportion of
2h
D
In any case, keep: < 600
t
(see AS1210, Table 3.12.5.1)
Chapter 2 Pressure Vessels 35
1 R
1/ 2
Where M = 3
4 r
R
M is a factor depending on
r
r/R > 0.06
or R/r < 16.66
hence R/r = 16.66 is the limit
(see AS1210, Table 3.12.5.2)
D
For safety reasons, keep < 100 otherwise, buckling due to the
t
setting up of localized stresses during the initial hydrostatic testing may
occur.
The actual pressure shell thickness must be larger than the minimum
calculated thickness.
Not recommended
(thin plates only)
Recommended
Single welded
Double welded
AS 1210, 1997
Compensation
- Plate thickness
- Welded vs bolted ends
- Gaskets may be needed for sealing
- Flange design must meet the Standards
- Gaskets need to be properly designed
- Supports for the flat ends
- See Fig 13.9, C & R, Vol 6
- Cylindrical
- Diameter 3 m
- L/D = 3
Mass=(26.0 kmole)(44kg/kmole)
= 1.14 tonnes 1.01bar 101kPa
1133 kg/tank
1133kg
No. of moles 25.75kmole
44kg / kmole
nRT
V
P
atm cm3
(25750mole)(82.05 )(298 K )
V moleK 63.0 106 cm3
(10atm)
V 63.0m3
L 8.9m
2.97
D 3m
Ok, close to 3
1 atm
10 atm D 3000mm
f 108MPa
0.7
t 19.97 mm
AS 1210 1997
Widths
Increments of 100 mm from 1200 mm to 3300 mm.
Thicknesses (mm)
5, 6, 8, 10, 12, 16, 20, 25, 28, 32, 36, 40 and so on.
Lengths
Increments of 200 mm from 4000 mm to 18000 mm.
Common sizes
Widths – 1800, 2400 mm, and 3000 mm
Lengths – 6000 mm and 9000 mm
Steel quality
- Pressure vessels from boiler grades
- Non-pressure vessels from structural grades
= 15.0 atm
fh
Where 1
f
63m3
L 11.0m
(1.35m) 2
L 11.0m
4.07
D 2.7 m
PD
t
2 f P
P 1MPa
D 2700mm
f 108MPa
0.7
t 17.97 mm
c 2mm
t total 19.97
P=1MPa = 1000kPa
D=3m or 2.7m
Pressure indicator
0.5
m = 17.97/20 = 0.90 P
t D
K = 3/0.90 = 3.33 Kf
0.5
1MPa
t 2700mm 170mm
3.33 108MPa 0.7
Chapter 2 Pressure Vessels 79
11.0 m
2.7 m
Alternatives
- Volume of head
Data provided by Australian Pressure
Vessel Heads Pty Ltd
tSE
PDK
K depends on D
2 f P
2h
D = 2731mm ID
D 2731
2.00
h =ITH = 682 2h 2(682)
K = 1.0
1MPa(2731)(1) 2731
tse 18.18mm
2(.7)(108) (1) 151
All dimensions are shown in millimetre’s (mm) with intermediate and hard metric sizes available on
request. For Head and End specifications, please refer to the following tables.
With the spinning process as tables below, diameters can be infinitely varied within the range. ie from
2850mm inside diameter to 6200mm outside diameter. The below table shows data for typical sizes
to assist in preliminary sizing only.
Weight Cubic End Thickness
Disc No.
End Diam Form ICR IKR ITH SF kg per Cap
Diam Pcs 10 12 16 20 25 28 32 36 40 50
10mm Litres
2896 ID SE 724 76 3556 2 780 3173
2896 ID TOR 2819 254 541 76 3327 2 682 2326
3048 ID SE 762 76 3759 2 871 3700
3048 ID TOR 2972 254 569 76 3505 2 757 2651
3353 ID SE 838 76 4153 2 1063 4925
3353 ID TOR 3277 279 624 76 3861 2 919 3523
3658 ID SE 914 76 4547 2 1275 6394
3658 ID TOR 3581 305 681 76 4191 2 1083 4575
3962 ID SE 990 76 4850 2 1450 8125
3962 ID TOR 3886 330 736 76 4572 2 1289 5806
4267 ID SE 1066 76 5131 2 1623 10150
4267 ID TOR 4191 356 793 76 4978 2 1528 7253
4572 ID SE 1143 76 5486 2 1856 12485
4572 ID TOR 4496 381 848 76 5309 2 1738 8913
4877 ID SE 1219 76 6200 3 2370 15154
4877 ID TOR 4801 406 904 76 6000 2 2220 10809
5182 ID SE 1295 76 6600 3 2686 18179
5182 ID TOR 5105 432 960 76 6300 3 2447 12970
5486 ID SE 1371 76 7000 3 3021 2686
5486 ID TOR 5410 457 1016 76 6600 3 2886 15378
5791 ID TOR 5715 508 1087 76 6708 3 2774 18491
6096 ID TOR 6020 508 1128 76 7027 3 3044 21089
Segmented Torispherical and Semi-Ellipsoidal Ends
In addition to the range of hot pressed and hot spun Torispherical and Semi-Ellipsoidal Ends we also
offer segmented versions.
The knuckle section will be hot pressed with the crown being either hot or cold pressed. Please refer
to the table for size range available, intermediate sizes are available on request. For diameters and
thickness outside of the range shown please contact our sales representatives.[See Dimensional Drawing
- Torispherical] [See Dimensional Drawing - Semi Ellipsoidal] [See Dimensional Drawing Abbreviations]
End Thickness in mm
End Diameter
25 28 32 36 40 45 50 55 60 70 80
3000
3500
4000
4500 HOT SPUN
5000
5500
6100
6200
6500
7000
7500
8000
Hemispherical Ends from 85mm to 1676mm ID and 6mm to 150mm thick, are hot pressed from a one
piece disk. Segmented hemispherical Ends are available as per the table, intermediate sizes are
available on request. For diameters and thickness outside of the range shown please contact our
sales representatives.[See Dimensional Drawing] [See Dimensional Drawing Abbreviations]
End Thickness in mm
End Diameter
12 16 20 25 28 32 36 40 45 50 55 60 70 80
2000
2500
3000
3500
4000
4500
5000
5500
6000
6500
7000
7500
8000
Inspection Openings
Elliptical Inspection openings are manufactured From certified boiler plate and are supplied complete
with neoprane gaskets. [See Dimensional Drawing] [See Dimensional Drawing Abbreviations]
All units are approved by the relevant statutory authority in each Australian State of Territory and
meet the requirements of:
• AS 1210 Unfired Pressure Vessel Code
• AS 1228 Water Tube Boiler Code
Nominal Weight Dimensions Maximum Design Pressure mPa at Degree C
No. of Bolts
Size (kg) L W H E T t Code 200o 250o 300o 350o 400o
AS1210 0.94 0.83 0.61 0.54
400 X 300 2 75 408 306 80 250 32 25
AS1228 0.99 0.77 0.69 0.59
AS1210 2.3 2.1 1.7 1.6
400 X 300 2 82 408 306 80 250 32 32
AS1228 2.25 1.9 1.75 1.6
AS1210 4.2 3.9 3.4 3.2
400 X 300 2 90 408 306 80 250 32 40
AS1228 4.1 3.55 3.35 3.1
AS1210 7.3 6.9 6 5.6
400 X 300 2 105 408 306 80 250 32 50
AS1228 7.05 6.15 5.8 5.45
AS1210 3.6 3.2 2.3 2
180 X 125 1 11 178 123 45 165 16 20
AS1228 3.7 2.9 2.6 2.25
115 X 90 1 6 113 88 40 130 12 16 AS1210 3.7 3.3 2.3 1.9
CHAPTER 3. NON-PRESSURE VESSEL DESIGN
Learning Objectives and Expectations
To be familiar with non-pressure vessel applications.
To understand the difference between pressure and non-pressure
vessels.
To become familiar with rules of thumb regarding vessel design.
To be familiar with design of very large storage tanks and small drums.
To be able to determine the minimum design thickness.
To be able to design and specify the details of safe non-pressure vessels.
To be able to design non-pressure vessels in a economically efficient
manner.
To be able to design tank farms.
To be able to produce non-pressure vessel specification sheets and
equipment sketches.
Non-Pressure Vessels
Buffer and Surge Tanks
(a) (b)
Figure 18.7. Key dimensions of knockout drums equipped with mesh pads
(a) Vertical knockout drum (b) Horizontal knockout drum
Chapter 3 Non-Pressure Vessels 7
2. LOADS
Storage
- Primary load is hydrostatic pressure of liquid or solid
- Secondary load such as wind, earth quake and other
equipment
Note these values are somewhat smaller than the minimum practical
wall thickness recommended for pressure and non-pressure vessels
due to the specifications required by AS 1692
Note these values are somewhat smaller than the minimum practical
wall thickness recommended for pressure and non-pressure vessels
due to the specifications required by AS 1692
Chapter 3 Non-Pressure Vessels 17
General guidelines
8. WALL THICKNESS
Minimum wall thickness
H gD
t L L 6t
2 f t10
HL = liquid depth (m)
L = liquid density (kg/m3)
= joint weld factor also J = joint factor
g = gravitational acceleration (9.81 m/s2)
ft = design stress for tank material (MPa)
Dt = tank diameter (mm)
t = wall thickness (minimum) (mm)
Small tanks
Constant wall thickness calculated at maximum liquid depth
Sometimes determined by requirement of rigidity rather than strength
(see table 13.5 C&R, Vol. 6)
Larger tanks
Economic reasons
Increase in hydrostatic pressure with depth
increase wall thickness with depth
Chapter 3 Non-Pressure Vessels 20
Note: The minimum wall thickness is based on the maximum
hydrostatic pressure (see previous page), but the vessel is
considered a non-pressure if it is subject only to pressures
caused by the static head of its contents .
As a general guide, the minimum practical wall thickness of non
supported walls: for both pressure vessels and non-pressure
vessels.
Vessel diameter Minimum wall thickness
(m) (mm)
<1.0 5
1.0 – 2.0 7
2 – 2.5 9
2.5 – 3.0 10
3.0 – 3.5 12
Extrapolate for larger diameters
The minimum practical wall thickness is set to ensure that any
vessel is sufficiently rigid to withstand its own weight. Note these
values are somewhat larger than category 4 and 5 AS 1692 tanks
due to the specifications
Chapterrequired by AS
3 Non-Pressure 1692
Vessels 21
R
sin and RC L2 R 2
RC
R
D
Chapter 3 Non-Pressure Vessels 23
- Width
- Thickness
- Length
- Material
10. LOCATION
12. SUPPORTS
(same as that for pressure vessel)
- Legs, brackets, saddles, skirts
- Flat bottom on concrete
13. INSTRUMENTS
- Level gauge
- Temperature and pressure indicator
- Alarms
Chapter 3 Non-Pressure Vessels 28
14. SAFETY DEVICES
- Overflow pipes
- Non pressure vent and breathers
- Pressure relief valve
- Bund
- Floating roofs
16. FILLING
- Possible damage to solid handled due to the fall.
- Possible damage to wall of silo for abrasive solids.
- Segregation of differing sizes
Chapter 3 Non-Pressure Vessels 29
Bins
Hoppers
Silos
20. NOTE
- Silo design is still an art
- Sometimes the properties of content are difficult to predict
- Best to copy existing design
Chapter 4 Piping 1
CHAPTER 4. PIPING
1. DEFINITION OF PIPING
Piping is an assembly of pipes, pipe fitting, valves, and pipe
accessories for containing fluids, including associated bolting,
gaskets, and pressure retaining parts, or other components
normally considered to be a part of piping. It includes pipe-
supporting elements, but does not include the structure such
as building frames and foundations. (AS4041, Clause 1.7.37)
2. IMPORTANCE OF PIPING
Typically 20% of investment cost
Without piping, chemical plant cannot operate
AS4041 available in the Uni library. (e-version + hardcopy)
search for SAI Global or under standards
Chapter 4 Piping 2
Chapter 4 Piping 3
Chapter 4 Piping 4
Chapter 4 Piping 5
3. STATUTORY REQUIREMENTS
Victorian registration is not required
Design must be recorded, verified, and the results kept for the life of the plant
The philosophy is ‘If it fails, you have to show that it was correctly designed’.
4. NATIONAL STANDARDS
- AS4041 Pressure Piping
- ANSI/ASME B31.1 Power Piping
- ANSI/ASME B31.3 Chemical Plant and Petroleum Refinery Piping
- BS806 Specification for the design and construction of ferrous piping
installations for an in connection with land boilers
- AS4041 takes the best of the overseas standards
- Allowed to use any approved national standard but not to mix
standards in the one application (AS4041, Clause 1.6)
- Standards set out the factors to be considered when designing,
supplying and erecting piping.
Chapter 4 Piping 6
5. COMPANY STANDARDS
- Mainly in bigger and especially oil companies
- May have to devise a set for the project
- Generally set out preferred options acceptable to the code,
e.g. flange ratings AS, ANSI or ISO and preferred options not
covered by the code, e.g. pipes in overhead or ground level
tracks.
6. PIPING CLASSIFICATION
- Table 1.4 and 1.5, AS4041
- Classes available - 1, 2A, 2P and 3
7. AIM OF CLASSIFICATION
Piping class is to give a high level of reliable performance and
adequate protection to life and property taking into account the
fluid and conditions inside the pipe.
Chapter 4 Piping 7
TABLE 1.4
APPLICATION OF PIPING CLASSES FOR SERVICE CONDITIONS
AS 4041, 2006
Chapter 4 Piping 8
AS 4343, 2005
Chapter 4 Piping 9
AS 4343, 2005
Chapter 4 Piping 10
Chapter 4 Piping 11
AS 4041, 2006
Chapter 4 Piping 12
AS 4041, 2006
AS 4041, 2006
Chapter 4 Piping 13
Chapter 4 Piping 14
AS 4041, 2006
Chapter 4 Piping 15
AS 4041, 2006
AS 4041, 2006
Chapter 4 Piping 16
8. DESIGN FACTORS TO BE CONSIDERED
- Nature of fluid – Lethal
Flammable
Toxic
Harmful to human tissue
Not harmful
Corrosive
- Consequences of failure
- Service condition – Design temperature
Design pressure
- Material of construction
- Thickness of pipe wall
- Quality of joints and welded seams
Chapter 4 Piping 19
The inside pipe diameter, i.d., is chosen to give the Schedule 40 and
Schedule 80 pipe an i.d. close to that specified by the DN code.
Chapter 4 Piping 22
Chapter 4 Piping 23
Chapter 4 Piping 24
When the pipe is bent, thinning of material occurs in the outside
of the bend. There is a limit to angle of bend, depending on wall
thickness and nature of material. When in doubt, use a fitting.
Chapter 4 Piping 25
Chapter 4 Piping 27
Chapter 4 Piping 28
17. PIPE ROUGHNESS
Only an approximation
See Table 3.3 Coulson and Richardson, Volume 1 and Walas
Table 3.3 Values of the roughness , for use in equation 3.92
Chapter 4 Piping 29
18. JOINTING
Welded - Most commonly used – usually with fittings
Flanged - Use in areas where access to pipe at regular internals is needed
used for final connection to process equipment.
Screwed - less used, small diameters only.
19. JOINTING WITH FITTINGS
Some commonly used ones are:
Straight union – for straight connections.
Elbows – fittings are usually used for 90o turns at the joint to
avoid bending the pipes by force. When pipes are bent,
stresses are built in the inside and outside of the bend,
and the pipe is weakened.
Tee - for branching
- direct welding of pipes to form the Tee joint, less preferred.
Reducer - for joining pipes of different diameter.
Usually forged or cast.
Fittings also have standard sizes made to fit the standard pipes
Wall thickness is also specified by the Australian and American Standards.
Chapter 4 Piping 30
butt weld cap
90o butt weld elbow 450 butt weld elbow
butt weld tee butt weld concentric reducer butt weld eccentric reducer
Chapter 4 Piping 31
Royston 5.13
C&R, Vol 1
Chapter 4 Piping 32
20. TYPES OF FLANGES
Chapter 4 Piping 33
Chapter 4 Piping 35
Chapter 4 Piping 36
AS 1210, 1997
full-face joint (gasket within bolt circle) (spigot and socket) (ring type joint)
narrow face joint Narrow face joint narrow face joint
Chapter 4 Piping 37
AS 1210, 1997
Chapter 4 Piping 38
23. STANDARD FLANGES
- Specified by rating
Chapter 4 Piping 39
Chapter 4 Piping 40
Chapter 4 Piping 41
Chapter 4 Piping 42
Chapter 4 Piping 43
Chapter 4 Piping 44
24. PRINCIPLES OF PIPING DESIGN
- Strikes a balance between the capital cost and the operating cost
- And yet handles the transportation of the fluid safely and efficiently
Chapter 4 Piping 45
Liquids
Pipes 1 – 3m/s
Water 1.5m/s to 2.5m/s
In Heat Exchanges
Shell side 0.3 – 1m/s
Tube side 1 – 3m/s
Vapors
Vacuum 50 – 70m/s
Atm pressure 10 – 30m/s
High pressure 5 – 10m/s
Chapter 4 Piping 47
The Bernouli equation represents the energy balance for the fluid
flow between two points in a piping network:
v12 v22
gh p gh1 P1 gh2 P2 gh f
2 2
Chapter 4 Piping 48
2
And h ( all K )
v
f i
2g
K i Equivalent number of velocity heads
fL
For straight pipe K
D
For other fittings see Table 6.4, Perry’s, and Table 3.2, C&R, Vol 1.
Note that these K values are rough estimates only, difficult to count
all the fittings and bends.
Once all K are counted -
fL v2
h f ( K1 K 2 )
D 2g
Straight Other
Pipe Resistances
Chapter 4 Piping 49
C & R Vol 1
Chapter 4 Piping 50
Perry’s
64
For Re <2100, f Darcy’s Friction Factor
Re
2
0.135 6.5 Note:
And Re>2100, f 1.6364 1n
D Re Fannings’ Friction
Factor is one quarter
(Eq. 6.2 Walas) of Darcy’s
Chapter 4 Piping 51
64 fL v
2
Darcy friction factor
Re D 2g
L v 64
2
Chapter 4 Piping 52
Chapter 4 Piping 53
Chapter 4 Piping 54
31. WALL THICKNESS OF STRAIGHT PIPE
tm = tf + G
Chapter 4 Piping 55
D
Thin wall pipe tf
6
D
Thick wall pipe tf
6
We will consider thin wall pipes only and steel pipe only (ferritic,
austenitic steel pipes).
Chapter 4 Piping 56
(b) based on id of pipe
Pd
tf 3.14.3 (2)
2 feM P
Where:
D = outside diameter (mm)
M = pipe class factor (Table 3.12.3)
d = inside diameter (mm)
e = weld joint factor or cast quality factor (Table 3.12.2)
f = design strength (MPa) (Table D2)
P = design pressure, (MPa)
tf = pressure design minimum wall thickness (in mm)
Safety Factors:
M = to allow for quality of the pipes
e = to allow for quality of longitudinal welding or allow for
quality of cast pipes.
Chapter 4 Piping 57
AS4041, 2006
Chapter 4 Piping 58
TABLE D2
AS 4041
2006
MATERIAL PROPERTIES, DESIGN PARAMETERS-CARBON, CARBON-MANGANESE
STEEL, PIPE AND TUBE
(not including joint factor or class design factor
Chapter 4 Piping 59
Chapter 4 Piping 61
The actual hoop stress, fa, during the pressure test shall not
exceed 90% of Re, the specified minimum yield strength.
f a 0.9 Re
Chapter 4 Piping 63
2. More difficult when pipes are used to handle utilities streams e.g. air,
steam
- Provide spare capacity for future demand?
- How much?
- How many branches?.
Chapter 4 Piping 64
25. PIPING DESIGN PROCEDURES
1. Establish process conditions
- Flow rate
- Fluid temperature and pressure
- Nature of fluid
2. Design preliminary run
3. Determine pipe size
4. Select material
5. Select piping class
6. Calculate ∆P
7. Calculate wall thickness
8. Determine testing procedure required
9. Establish testing parameters
10. Perform flexibility analysis
11. Establish final piping layout
Chapter 4 Piping 65
Chapter 4 Piping 66
All pipes should be
vertical or horizontal
and orthogonal to each
other.
Chapter 4 Piping 67
Chapter 4 Piping 68
- Water at room temp
- Non-corrosive
- Carbon steel
kg
3.889
V s
1000 kg 3
m
3
3.889 10 3 m
s
TABLE 1.4
Application of piping classes for service conditions
AS4041, 2006
Chapter 4 Piping 70
Select pipe size
V
v 2.0 m
A s
V 3.889 103 m 3 / s
A 0.00194m 2
v 2m / s
A 0.00194m 2 A R 2
A 0.00194m 2
R 0.0248m
D = 0.0497 m = 49.7 mm
Select nearest standard pipe size
Select DN50, try Schedule 80
Chapter 4 Piping 71
Chapter 4 Piping 72
o.d = 60.3 mm kg
3.889
Wall t = 5.54 mm V s
1000 kg
i.d. = 49.22 mm m3
4
V 3.889 103 m3 / s
1.903 10 3 m 2 v 2.044m / s
A 1.903 103 m 2
V
v 2.044 m
A s
OK
Chapter 4 Piping 73
fL v2
2
h f K i
P1 v12 P2 v22 D 2g
hp h1 h2 hf
g 2g g 2g
L 30 10 8m
v1 0 Large reservoir
48m
P1 P2 latm
K i : in no of velocity heads
Elbows 2 x 0.75 =1.50
v22
hp h f h2 h1 Straight union 7 x 0.04= 0.28
2g
Flanges 4 x 0.04= 0.16
Chapter 4 Piping 74
Pump should be near
the source.
Chapter 4 Piping 75
C & R Vol 1
Chapter 4 Piping 76
Perry’s
fL v2
2
h f K i
P1 v12 P2 v22 D 2g
hp h1 h2 hf
g 2g g 2g
L 30 10 8m
v1 0 Large reservoir
48m
P1 P2 latm
K i : in no of velocity heads
Elbows 2 x 0.75 =1.50
v22
hp h f h2 h1 Straight union 7 x 0.04= 0.28
2g
Flanges 4 x 0.04= 0.08
Chapter 4 Piping 77
2
0.135 6.5
f 1.6364ln
D Re
v 2.044 m
s
1000 kg
m3
110 3 kg ms
D 0.0492m
Dv
Re 100606
Chapter 4 Piping 79
Chapter 4 Piping 80
FRICTION LOSS PUMP HEAD
fL 0.0226 48m v2
D
0.0492m 0.213m
2g
v2
30.07
2g
2
m
30.07 2.044
s
hf
2 9.81 m s 2
6.40m of water head
Chapter 4 Piping 81
P1 v12 ht hp hs
hs h1
g 2g
ht 13.6m 13.33m
v1 0 26.9m of water
hf 0
The maximum pressure in the pipeline
will be that just after the pump. So use
101,300 the value of ht -1 atm (the pressure
hs 3m outside of the pipe) to determine the
1000 9.8
design pressure.
hs 3m 10.33
hs 13.33m of water head P g (ht hatm )
Chapter 4 Piping 82
Pd
WALL THICKNESS tf
2 feM P
d 49.22mm
t f 0.031mm
For liquid – pressure pipe not needed.
Add corrosion allowance = 2mm, still very thin.
Chapter 4 Piping 83
TABLE D2
AS 4041
2006 MATERIAL PROPERTIES, DESIGN PARAMETERS-CARBON, CARBON-MANGANESE
STEEL, PIPE AND TUBE
(not including joint factor or class design factor
Chapter 4 Piping 84
AS4041, 2006
Chapter 4 Piping 85
- DN50, diameter ok
Chapter 4 Piping 86
AS 4041, 2006
Chapter 4 Piping 87
AS4041,2006
Chapter 4 Piping 88
Chapter 4 Piping 89
AS 4041, 2006
CLASS 3
-100o TO 180oC
CLASS 2P
0 to 99oC
Chapter 4 Piping 91
- Structural support
Chapter 4 Piping 94
PIPELINE WORKED EXAMPLE 2
Design pressure piping for steam.
Operating P = 4500-5000 kPa Gauge
Operating T = 340-360oC
Superheated steam is to be conveyed.
What wall thickness is required?
What hydrostatic test P should be applied?
Given, but normally need to
V
DN200 PIPE IS TO BE USED calculate from v
A
Using a target velocity
Use AS4041 Pressure Pipe
Fluid type - Tables 1.4 and AS 4343
Fluid No. 2 - harmful to human tissue, class 2P is excluded
Chapter 4 Piping 95
TABLE 1.4
APPLICATION OF PIPING CLASSES FOR SERVICE CONDITIONS
AS 4041, 2006
Chapter 4 Piping 96
AS 4343, 2005
Chapter 4 Piping 97
Chapter 4 Piping 98
TABLE D2
AS 4041
2006 MATERIAL PROPERTIES, DESIGN PARAMETERS-CARBON, CARBON-MANGANESE
STEEL, PIPE AND TUBE
(not including joint factor or class design factor
Chapter 4 Piping 99
tm = tf + G
tm = 5.15 + 3 + 0.125 tm
tm = 9.19 mm
Check with pipe line data sheet
Sch’d 40 w.t. = 8.18 mm
Sch’d 80 w.t. = 12.7 mm
Select Schedule 80
o.d. = 219.08 mm
i.d. = 193.68 mm Chapter 4 Piping 102
Extra Strong is the same as Schedule 80
Recalculate using
i.d. = 193.68 mm,
But tm won’t change much
Carbon steel, ok
Table 1.5
Common method is to fill the pipes with cold water, and pump up to the
required pressure.
f 101MPa
Re 276 MPa
Ph 11.34 MPa
Chapter 4 Piping 107
TABLE D2
AS 4041
2006 MATERIAL PROPERTIES, DESIGN PARAMETERS-CARBON, CARBON-MANGANESE
STEEL, PIPE AND TUBE
(not including joint factor or class design factor
Ph D
fa
2t
fa
11.34 MPa 219.08mm
2 12.70mm
= 97.8 MPa
Re = Specified min. yield stress
fa<0.9 Re
OTHER ISSUES
Welding method
Fittings
Structural support
Record keeping
Call 1300 66 11 56
Fax (03) 8543 1146
Formula to attain approximate mass in kilograms per metre (kg/m) for Steel Round Pipe and Tubing
{ {
m = (D – t) t x 0.02466 Nominal Size Step 1. 323.9 – 9.53 = 314.37
Where, DN300 NPS12 Step 2. 314.37 x 9.53 = 2995.9461
EXAMPLE: OD = 323.9mm Step 3. 2995.9461 x 0.024 66
m = mass to the nearest 0.01 kg/m
D = Outside Diameter in millimetres W.T. = 9.53mm = 73.88kg/m
(To nearest 0.1mm for OD up to 406.4mm)
(To nearest 1.0mm for OD 457mm and above)
t = Wall Thickness to nearest 0.01mm
NOMINAL SIZE
CLASS 150 (PN20) 15 20 25 32 40 50 65 80 100 125 150# 200# 250 300 350 400 450 500 600
OD A 90 100 110 120 130 150 180 190 230 255 280 345 405 485 535 600 635 700 815
MIN THICK* D 11.5 13.0 14.5 16.0 17.5 19.5 22.5 24.0 24.0 24.0 25.5 29.0 30.5 32.0 35.0 37.0 40.0 43.0 48.0
HUB LENGTH** C 16 16 17 21 22 25 29 30 33 36 40 44 49 56 57 64 68 73 83
HUB LENGTH W/N B 48 52 56 57 62 64 70 70 76 89 89 102 102 114 127 127 140 145 152
PCD K 60.5 70.0 79.5 89.0 98.5 120.5 139.5 152.5 190.5 216.0 241.5 298.5 362.0 432.0 476.0 540.0 578.0 635.0 749.5
BOLT HOLE DIA H 16 16 16 16 16 20 20 20 20 22 22 22 26 26 30 30 33 33 36
No BOLTS 4 4 4 4 4 4 4 4 8 8 8 8 12 12 12 16 16 20 20
WEIGHT Kg*** 0.5 0.7 1.0 1.1 1.4 2.2 3.8 4.1 5.9 6.1 8.2 12.7 17.2 27.2 35.4 42.2 52.6 65.3 91.6
WEIGHT Kg W/N 0.8 0.9 1.1 1.4 1.8 2.8 4.4 5.2 7.5 9.5 11.3 19.1 25.4 38.1 51.3 63.5 74.9 89.4 121.7
WEIGHT Kg BLIND 0.9 0.9 0.9 1.4 1.8 2.3 3.2 4.1 7.7 9.1 12.0 21.4 30.5 50.6 63.0 85.0 99.0 129.0 190.0
CLASS 300 (PN50) 15 20 25 32 40 50 65 80 100 125 150# 200# 250 300 350 400 450 500 600
OD A 95 120 125 135 155 165 190 210 255 280 320 380 445 520 585 650 710 775 915
MIN THICK* D 14.5 16.0 17.5 19.5 21.0 22.5 25.5 29.0 32.0 35.0 37.0 41.5 48.0 51.0 54.0 57.5 60.5 63.5 70.0
HUB LENGTH** C 22 25 27 27 30 33 38 43 48 51 52 62 67 73 76 83 89 95 106
HUB LENGTH W/N B 52 57 62 65 68 70 76 79 86 98 98 111 117 130 143 146 159 162 168
PCD K 66.5 82.5 89.0 98.5 114.5 127.0 149.0 168.5 200.0 235.0 270.0 330.0 387.5 451.0 514.5 571.5 628.5 686.0 813.0
BOLT HOLE DIA H 16 20 20 20 22 20 22 22 22 22 22 26 30 33 33 36 36 36 42
No BOLTS 4 4 4 4 4 8 8 8 8 8 12 12 16 16 20 20 24 24 24
WEIGHT Kg*** 0.7 1.3 1.4 2.0 2.8 3.1 4.5 6.1 9.5 12.7 16.3 25.4 35.4 50.8 72.2 95.3 114.9 139.4 222.3
WEIGHT Kg W/N 0.9 1.4 1.8 2.3 3.1 3.7 5.6 8.2 11.8 16.3 20.0 32.2 45.4 64.4 93.5 113.1 138.4 167.5 235.6
WEIGHT Kg BLIND 0.9 1.4 1.8 2.7 3.2 3.6 5.5 7.3 12.7 16.8 21.8 35.9 55.0 83.0 110.0 143.0 188.0 234.0 364.0
CLASS 600 (PN100) 15 20 25 32 40 50 65 80 100 125 150# 200# 250 300 350 400 450 500 600
OD A 95 120 125 135 155 165 190 210 275 330 355 420 510 560 605 685 745 815 940
MIN THICK* D 14.5 16.0 17.5 21.0 22.5 26.5 29.0 32.0 38.5 44.5 48.0 55.5 63.5 66.5 70.0 76.5 83.0 89.0 102.0
HUB LENGTH** C 22 25 27 29 32 37 41 46 54 60 67 76 86 92 94 106 117 127 140
HUB LENGTH W/N B 52 57 62 67 70 73 79 83 102 114 117 133 152 156 165 178 184 190 203
PCD K 66.5 82.5 89.0 98.5 114.5 127.0 149.0 168.5 216.0 267.0 292.0 349.0 432.0 489.0 527.0 603.0 654.0 724.0 838.0
BOLT HOLE DIA H 16 20 20 20 22 20 22 22 26 30 30 33 36 36 39 42 45 45 52
No BOLTS 4 4 4 4 4 8 8 8 8 8 12 12 16 20 20 20 20 24 24
WEIGHT Kg*** 0.9 1.4 1.6 2.0 3.0 3.6 5.5 6.8 15.0 28.6 36.3 44.0 80.4 97.6 117.6 166.2 216.1 277.9 397.7
WEIGHT Kg W/N 1.4 1.6 1.8 2.5 3.6 4.5 6.4 8.2 16.8 30.9 38.1 50.6 85.8 102.6 157.5 218.4 252.0 313.3 443.6
WEIGHT Kg BLIND 0.9 1.4 1.8 2.7 3.6 4.6 6.8 9.1 18.6 30.9 39.1 63.0 105.0 134.0 172.0 240.0 302.0 389.0 534.0
* MINIMUM THICKNESS INCLUDING RAISED FACE BUT EXCLUDING HUB OR WELD NECK
** HUB LENGTH FOR SLIP ON SCREWED & SOCKET WELD FLANGES
*** APPROXIMATE WEIGHT FOR SLIP ON SOCKET WELD & SCREWED
# OD OF PIPE MUST BE NOMINATED
7 Forged ANSI B16.5 Forged Flanges Forged ANSI B16.5 Forged Flanges 8
FLANGE ASME B16.5 FORGED FLANGES 8
NOMINAL SIZE
CLASS 900 (PN150) 15 20 25 32 40 50 65 80 100 125 150# 200# 250 300 350 400 450 500 600
OD A 240 295 350 380 470 545 610 640 705 785 855 1040
MIN THICK * D 38.5 44.5 51.0 56.0 63.5 70.0 79.5 86.0 89.0 102.0 108.0 140.0
HUB LENGTH** C USE CLASS 1500 DIMENSIONS 54 70 79 86 102 108 117 130 133 152 159 203
HUB LENGTH W/N B 102 114 127 140 162 184 200 213 216 229 248 292
PCD K 190.5 235.0 279.5 317.5 393.5 470.0 533.5 559.0 616.0 686.0 749.5 901.5
BOLT HOLE DIA H IN THESE SIZES 26 32 35 32 39 39 39 42 45 52 54 68
No BOLTS 8 8 8 12 12 16 20 20 20 20 20 20
WEIGHT Kg*** 14.1 24.1 37.7 49.0 78.1 111.2 148.0 172.5 208.4 293.7 359.6 671.9
WEIGHT Kg W/N 13.2 23.2 39.0 49.9 84.9 121.7 168.9 255.2 311.0 419.5 528.5 956.6
WEIGHT Kg BLIND 14.0 24.6 39.6 51.0 90.0 132.0 188.0 225.0 281.0 400.0 503.0 954.0
CLASS 1500 (PN250) 15 20 25 32 40 50 65 80 100 125 150# 200# 250 300 350 400 450 500 600
OD A 120 130 150 160 180 215 245 270 310 375 395 485 585 675 750 825 915 985 1170
MIN THICK * D 22.5 25.5 29.0 29.0 32.0 38.5 41.5 48.0 54.0 73.5 83.0 92.0 108.0 124.0 133.5 146.5 162.0 178.0 203.5
HUB LENGTH** C 32 35 41 41 44 57 64 73 90 105 119 143 159 181
HUB LENGTH W/N B 60 70 73 73 83 102 105 118 124 155 171 213 254 283 298 311 327 356 406
PCD K 82.5 89.0 101.5 111.0 124.0 165.0 190.5 203.0 241.5 292.0 317.5 393.5 482.5 571.5 635.0 705.0 774.5 832.0 990.5
BOLT HOLE DIA H 22 22 26 26 30 26 30 33 36 42 39 45 52 56 60 68 76 80 94
No BOLTS 4 4 4 4 4 8 8 8 8 8 12 12 12 16 16 16 16 16 16
WEIGHT Kg*** 2.7 2.7 3.4 4.5 6.4 10.0 16.3 21.8 33.3 59.9 74.5 117.1 197.9 302.8
WEIGHT Kg W/N 3.2 3.2 3.9 4.5 6.4 10.9 16.3 21.8 31.3 59.9 74.5 123.9 206.1 313.3
WEIGHT Kg BLIND 1.8 2.7 4.1 4.6 6.4 11.4 15.9 21.8 33.2 65.0 72.0 137.0 230.0 352.0
* MINIMUM THICKNESS INCLUDING RAISED FACE BUT EXCLUDING HUB OR WELD NECK
** HUB LENGTH FOR SLIP ON, SCREWED & SOCKET WELD FLANGES
*** APPROXIMATE WEIGHT FOR SLIP ON, SOCKET WELD & SCREWED
# OD OF PIPE MUST BE NOMINATED
FLANGES ABOVE DN 600 ARE NOT INCLUDED IN ASME B16.5 AND THE CLASS DESIGNATIONS IN THESE
LARGE DIAMETERS DO NOT IMPLY SPECIFIC TEMPERATURE/PRESSURE RATINGS.
Pipe spacing.
From Royston
By Royston
4. LOCATING VALVES
- Must be accessible for adjusting flow rates
By Royston
Top Ok,
bottom for condensate drainage
6. THERMAL EXPANSION
- Heated pipes expand and generate large forces
- Build in flexibility
By Royston
9. CLEANING
- Before using a pipe for the first time or after shut down, check
that inside is clear of debris
- Some systems need special treatment, hygienic for food
- Degree of cleanliness depends on the service
By Royston
Dy
208
L u 2 (AS4041, 3.27.2.2)
(a) 200 m
X X
70 m
X
(b)
20 m
X
(219)(958)
208 a 15.9m
200 2a 2002
The expansion loop should be greater than 15.9 m to avoid formal
flexibility analysis.
(b) 70 m
X
20 m y (11.4 10 6 )(72.8)(420) 0.349m
u 70 2
20 2 72.8m
X
Dy (219)(349)
208 258 208
L u 2 90 72.82
Formal flexibility analysis would be needed, so lets design an
expansion loop.
70 m
(219)(349) b b
208 X
90 2b 72.82 20 m
X
b 0.985m
Chapter 6 Valves 1
CHAPTER 6. VALVES
1. TYPES OF VALVES
(a) Manual valves
- For stopping and starting flow
* Isolating a unit
* By-passing a section of the plant
- For manual flow rate control
- For diverting flow
* Such as 3-way valves
- For handling complex fluid, e.g. fluid with solid in suspension
(b) Check valve
- For preventing reverse flow
* One way valves
(c) Pressure relief valve
- Relieving a system of excess pressure
(d) Actuator
- Electrically or pneumatically driven
- For automatic flow rate control
Chapter 6 Valves 2
2. MANUAL VALVES
This is sub-classified according to the way the closure member moves
onto the seat.
(a) Close down valves
- A disk like closure member is moved squarely to and from the seat
in the direction of stem axis: e.g. globe valves.
- Opening varies in direct proportion to the travel of the disc
- This proportionality makes the valve ideal for regulation of flow rate.
Globe valves
Gate valves
Plug valves
Chapter 6 Valves 5
Zappe
Ball valves
C&R vol 6
Chapter 6 Valves 6
Chapter 6 Valves Royson 7
Royson
Chapter 6 Valves 8
Perry
Zappe
Chapter 6 Valves 9
Pinch Valves
Chapter 6 Valves 10
3. MANUAL VALVE SELECTION
Zappe
Chapter 6 Valves 11
4. CHECK VALVES
A valve which opens with forward flow and closes against reverse flow.
Perry
4. CHECK VALVES
A valve which opens with forward flow and closes against reverse flow.
Perry
McCabe and Smith
Chapter 6 Valves 14
4. CHECK VALVES
A valve which opens with forward flow and closes against reverse flow.
Zappe
Chapter 6 Valves 15
Chapter 6 Valves 16
Chapter 6 Valves 17
Rupture Disc
Spring Operated
Chapter 6 Valves 22
6. ACTUATOR
A valve controlled electrically or pneumatically to open to a definite
extent so that a pre-set flow rate is obtained.
Chapter 6 Valves 23
8. MATERIAL OF CONSTRUCTION
- Selection based on T & P of operation
- Also based on nature of fluid
- Cast iron
- Carbon steel
- Stainless steel
- Brass and bronze
- PVC and other plastics
9. VALVE SEALS
(a) A fluid seal – the seal between the seat and the closure e.g. a
gate, a piston member, a globe
(b) A gland seal – the seal between the valve stem and union
bonnet/bonnet nut
Chapter 6 Valves 26
10. STEM-GLAND SEAL
- Compression packing under the gland nut – inert packing
- ‘O’ ring – rubber or synthetic rubber
- Flat Teflon washer
- Atom class
- Steam class
- Low leakage class
- Nominal leakage class
Chapter 6 Valves 28
CHAPTER 7. PUMPING EQUIPMENT FOR LIQUIDS
Learning Objectives and Expectations
To understand the fundamental differences between pumping liquids and
gasses.
To understand the difference between displacement and dynamic pumps.
To be familiar the operation of various types of pumps and their typical
applications.
To be able to select a type of pump based on inlet flow rate and outlet
pressure (head).
To be able to select the impeller size for a centrifugal pump based on
maximising efficiency using pump performance curves.
To be able to determine NPSH required and pump power.
Understand the use of throttling valves and how to avoid cavitation.
To be able to use pump affinity laws to make modifications to existing
pumps to change the duty point.
Chapter 7 Pumps 1
2. ENERGY TRANSFER
- The energy appears in the fluid as an increase in pressure or
velocity or both
3. CONVENTIONAL CLASSIFICATION
- Pump – the fluid is substantially incompressible, e.g. liquids.
- Compressor – the fluid is significantly compressible under the
pumping conditions, e.g. air includes blower, fans, vacuum pump.
Chapter 7 Pumps 2
4. TRANSFERRING GAS VERSUS LIQUID
- Same basic type of mechanical equipment, but very different
construction.
- Lower density for gas, higher speed of operation
- For gas, volume decreases as it is compressed
- Cooling of gas may be needed
- Compression is carried out in a number of stages with cooling in
between.
- Compression and expansion of residual gas in cylinder (energy for
compression and expansion are not completely recoverable).
6. DRIVES
- Electrical motor, all sizes
- Steam turbine, large size
- Gas turbine, large size
- Compressed gas, mainly compressed air
Chapter 7 Pumps 3
Perry
Chapter 7 Pumps 4
TYPES OF PUMPS
Chapter 7 Pumps 5
radial axial
Chapter 7 Pumps 6
Perry
Chapter 7 Pumps 7
Centrifugal pumps
Chapter 7 Pumps 8
Turbine pump
Diffuser Type
Centrifugal pump
Stationary Vanes
Chapter 7 Pumps 9
Chapter 7 Pumps 10
Perry
Chapter 7 Pumps 11
Chapter 7 Pumps 12
(2) Positive displacement pumps
- Fluid is displaced (pushed along) under pressure
- Much lower capacity, much higher dynamic heads or discharge pressure
- For viscous fluids
- Flow rate depends mainly on pulsation rate or gear rotary rate.
(a) Reciprocating pump
(i) The piston pump
- Consists of a cylinder with a reciprocating piston connected to
a driving-rod which passes through a gland.
- Liquid enters the suction line through a suction valve
- Liquid is discharged through a delivery valve
- Single acting – deliver liquid in forward stroke, not backward
stroke
- Double acting – deliver liquid in both forward and backward
stroke.
(ii) The plunger pump
- Same in principle as the piston type
- The gland is located at one end of cylinder making it easier to
replace.
Chapter 7 Pumps 13
Rhodes
Chapter 7 Pumps 14
C&R Vol 1
Chapter 7 Pumps 15
Chapter 7 Pumps 16
Chapter 7 Pumps Diaphragm pump C&R Vol 17
1
Chapter 7 Pumps 18
(b) Rotary pumps
Liquid is (displaced) pushed along by rotating gear and screw
housed in a chamber which has been carefully designed in shape
and size.
No valves
Small clearance between gear wheels and the case
More even flow than reciprocating pump
Chapter 7 Pumps 19
Perry
Chapter 7 Pumps 20
Gear pumps
Chapter 7 Pumps 21
Chapter 7 Pumps 22
(ii) Mono Pump
- A specially shaped helical rotor
- Revolves in a specially shaped housing
- A cavity is formed continuously as the rotor turns
- The fluid advance gradually toward the discharge end
- Uniform flow
- Can handle corrosive and gritty liquids, e.g. slurries
- Should never run dry
- Can pump against high pressure
- The higher the delivery pressure, the longer the rotor that is needed
Chapter 7 Pumps 23
C&R Vol 1
Chapter 7 Pumps 24
C&R Vol 1
Chapter 7 Pumps 25
Chapter 7 Pumps 26
305 m =
30.5 m =
Perry
Chapter 7 Pumps 27
Chapter 7 Pumps 28
Chapter 7 Pumps 29
Walas
Walas
Chapter 7 Pumps 30
9. SELECTION OF PUMP SIZE AND POWER
- Pump size selection data sheets usually provided by supplier, (see
KSB, data sheets next pages and on LMS)
- Volumetric flow rate
- Total head
Once a specific size pump has been selected, other data concerning
physical nature of the pump are also usually provided by the supplier
- Pump dimensions
- Power of motor
- Weight
- Connection to pipes, flanges usually inlet and outlet pipe dimensions
- Speed of pump
- Configuration of pump feet
More importantly, a pump performance curve diagram is also available.
- Pump head vs flow rate
- Pump efficiency, power consumption, and NPSHR
e.g. commonly used is centrifugal pump turning at 1450 rpm with feet
mount on common base plate with electric motor.
Chapter 7 Pumps 31
Chapter 7 Pumps 32
KSB Mega series pumps
Chapter 7 Pumps 33
Chapter 7 Pumps 34
Chapter 7 Pumps 35
Chapter 7 Pumps 36
Chapter 7 Pumps 37
30 to 35 L/s 18 to 20 m head
Chapter 7 Pumps 38
= 0.73
Chapter 7 Pumps 39
= 0.76
Chapter 7 Pumps 40
= 0.67
Chapter 7 Pumps 41
Vgh p VP
Power
.
Where V = volumetric flow rate (m3/s)
= density (kg/m3)
Chapter 7 Pumps 42
10. PUMP AND SYSTEM CHARACTERISTIC CURVE
P v2
h p ( system) h h h fd
g 2 g fs
Where hfs = friction head on the inlet side (suction side)
hfd = friction head on the outlet side (discharge side)
.
For V =0, v = 0, hfs =0 and hfd =0,
we get hp = h + P/g = ho + P/g
.
For V =0 and P = 0, we get hp = h = ho
Chapter 7 Pumps 43
system curve
performance curve the relationship
between required
head and volumetric
flow rate of your
piping system
duty point
Note h = z
.
= V = volumetric flow rate
Chapter 7 Pumps 44
Note h = z
Chapter 7 Pumps 45
Pump curve: If the co-ordinates of three points on the curve are obtained,
then the constants a, b, and c can be obtained by solving
the three equations simultaneously.
System curve:If the co-ordinates of two points on the curve are known , the
constants a’ and c’ can be determined
.
co-ordinate (V, hp) = (0, h0) is always useful.
dh p
2a 'V
dV
. dhp
at V = 0, 0 This boundary condition must hold for Eq.2.
dV
Chapter 7 Pumps 46
System Curve – determined with Bernouli’s eqn
v 2 P
hp h f h For constant diameter pipe
2g g
V
= Av
V v=
fL V
2
P A
h p K i 2 h =0
D 2A g g 1 ≈ V
For long pipe: V 2 , ∆V
h p aV 2 c
fL
K i P
Where a
D and c h
2 A2 g g
h
= 0, v = 0, ∆P=0 and h = 0
At V system curve
f (dynamic
velocity
Then hp = ∆h head)
dh p (static
And 0 gravity ∆h
dV head)
V
Chapter 7 Pumps 47
e.g. between 283 and 310 mm for centrifugal pumps M65-315, this
allows later change of impeller diameter.
Chapter 7 Pumps 48
Chapter 7 Pumps 49
If you can’t match a performance curve to the flow rate you want, you
should add a throttling valve just downstream of the pump so that you can
control the flow rate to get the desired flow rate.
throttling
valve
. .
Desired V V
Chapter 7 Pumps 50
15. EXAMPLE USE OF PERFORMANCE CURVE AND DUTY POINT
Replacing an existing Impeller – centrifugal pump
2
h p2 D
2
h p1 D1
3
P2 D 2
P Power
P1 D1
Chapter 7 Pumps 51
, hp = (0, h0)
V
5. Draw the system curve and locate the new Duty Point, 2.
Make sure that this falls on the pump curve properly.
Chapter 7 Pumps 54
Cavitation
Chapter 7 Pumps 55
To avoid cavitation,
Require P > Pvp (vapour pressure at current T)
This condition is expressed in terms of the
NET POSITIVE SUCTION HEAD (HPSH)
Pvp
NPSH = hs
g
h1
Chapter 7 Pumps 56
17. NET POSITIVE SUCTION HEAD, NPSH
NPSH must exceed a certain value (i.e. the vapor pressure head of
liquid) in order to prevent vaporization of the liquid and cavitation of
the metal.
Static Friction head Vapor NOTE: do not
NPSH = Pressure head + suction - in Suction - pressure head subtract
at source head line of liquid velocity head
2
P1 fL v P when v1 = 0
NPSH h1 ΣK i v and v2 = v
ρg D 2g ρg
Chapter 7 Pumps 57
P1 Pvp
Available NPSH = h1 h fs
g
Chapter 7 Pumps 58
PB P
Define 1 h1 h fs NOTE: do not subtract
g g velocity head
PB PV
When NPSH >0, , flow is satisfactory.
g g
PB PV , liquid will start to vaporize.
When NPSH < 0,
g g
Chapter 7 Pumps 59
Chapter 7 Pumps 61
NPSHR
(required)
Chapter 7 Pumps 62
NPSHR
(required)
Chapter 7 Pumps 63
The second pump must be started only after the first is running
otherwise there may be problems in the suction of the second.
The extra resistance may cause problems with NPSH.
For a given system when the two pumps are running each pump
will be develop a smaller head than when one is running on its
own.
Royston
Chapter 7 Pumps 64
Chapter 7 Pumps Royston 65
(a) Two pumps operating in parallel will deliver less than twice the
flow rate of an individual pump operating by itself in the same
system (due to increased friction with two pumps). It will also be
noted that the increase in quantity obtained by placing two pumps
in parallel is determined by the shape of the system resistance
curve. Thus, if there is considerable friction (as indicated by the
dotted line), two pumps in parallel may deliver only slightly more
than one pump operating by itself.
(b) One pump by itself will operate at a higher flow rate (A) than if it
were working in parallel with another pump (B). In other words, it
would be operating further out the curve, possible with greater
power requirements. Therefore when a pump is designed for a
parallel duty, also ensure that the driver is adequately rated for solo
operation.
Chapter 7 Pumps 66
Royston
Chapter 7 Pumps 67
(5) Obtain pump performance curve and check the duty point on
the curve (pump characteristic) curve
.
Duty point = (V, hp)
Duty point
hp
.
V
(6) Specify the motor power rating using actual power calculation
(7) Specify inlet and outlet pipe dimension and connection types
Chapter 7 Pumps 70
PUMPS WORKED EXAMPLE 1
EXAMPLE USE OF PUMP SELECTION
Chapter 7 Pumps 71
P2 = 1 atm
30 m
18 m
3m 8m
P1 = 1 atm
Chapter 7 Pumps 72
. .
Flow rate = m = 65 tonnes/hr (1) Determine V
= 65000 kg/hr
.
P1 = P2 = 1 atm m = 65 000 kg/hr
. .
Large tank at source V = m = 65 m3/hr
so v1 = 0, v2 = v
= 1000 kg/m3 .
V = 1.806 x 10-2 m3/s
= 1x10-3 kg/ms
v 2 P
hp h h f
2g g
2
fL v
hf K i
D 2g
Chapter 7 Pumps 73
Chapter 7 Pumps 74
Standard is the same as Schedule 40
Chapter 7 Pumps 75
fL v
2 ΣKi Contraction 1x0.5 = 0.5
hf K i Expansion 1x0.5 = 0.5
D 2g Elbows 2x0.75 = 1.5
Flanges 5x0.04 = 0.20
2 Straight Unions 7x0.04 = 0.28
0.135 6.5 Globe Valve (open) 1x6 = 6
f 1.634 ln
D Re Gate valve (1/2 closed) 1x4 = 4
---------------------------
Dv2 ΣKi = 12.98
Re 225060
0.05
K i 12.98
Chapter 7 Pumps 76
C & R Vol 1
Chapter 7 Pumps 77
Perry’s
L 8 18 30 56m
P
0 Since P1 = P2
fL g
10.4
D
h p 5.76 0.246 15 0
2
v
h f (10.4 12.98) 2
21.0m of water
2g
V 18L / s
h f 5.76m of water
V 65m3 / hr
h 18 3 15m of water
Chapter 7 Pumps 78
hp 21.0m (4) Select Pump Type
69 ft .
Use V, hp
V 18 L / s Table 10.16 C&R
284gal / min
Fig. 10.-26 Perry
with
Select Centrifugal pump ok
3.8 L 1gal
3.28 ft 1m
Chapter 7 Pumps 79
65 m3/hr 21.0 m
X
X
Chapter 7 Pumps 80
21 m
= 69 ft
Chapter 7 Pumps 81
Elite E65-26
(6) Select Propeller Size
21.0 m
18 L/s
Chapter 7 Pumps 83
21.0 m
System curve
Choose 264 mm
h = 15 m diameter impeller
closest one (above)
65 m3/hr = 18 L/s
Chapter 7 Pumps 84
Desired flow rate
= 18 L/s
Efficiency = = 0.755
NPSHR = 2.2 m
Power = 5.2 kW
Chapter 7 Pumps 86
(7) Check Power Consumption
3.71kW
Power 4.91kW
0.755
≈ 5.2 kW Ok, checked
Previous page
(8) Flanges
- Flange Connection between pump & piping
- Order flanges that will match those on the pump
- Need pipe reducer on inlet
DN100DN80, next page
- Need pipe expander on outlet
DN65DN100, next page
Chapter 7 Pumps 87
Chapter 7 Pumps 88
(9) Pump Dimensions
- Will replacement pump fit into existing space?
- Leave lots of room around pump for heat dissipation and motor
L = a + f = 570 mm
H = h1 + h2 = 450 mm
Chapter 7 Pumps 89
(0.726)(0.408
0.246 m )
PB P
1 h1 h f 1 0.3
0.18mm of water
g g
fL v
2 P1
101 10 3 kgm / s 2
hf 1
D
Ki
2g
g 1000 kg / m 3 9 .81m / s
fL 0.019 1m PB
10 . 3 3 0 . 18 13 . 12 m of water
0.186
D 0.102m g
K i : 1 contraction = 0.5
Pv 0 .02337 bar at 20oC
1 flanges = 0.04
(1 bar = 105 kg/ms2)
K i 0.54
Chapter 7 Pumps 90
Pv 2337kg / ms 2
Pv
0.238m of water
g
P P
B v
g g
P P - Consult pump supplier’s data
NPSH B Pg 86 NPSHR = 2.2 m of water
g g
NPSH 13.12 0.238m - NPSH >>NPSHR
NPSH 12.88m of water Unlikely to have vaporisation problems
- Foundation
- Isolation valves
Chapter 7 Pumps 92
PUMPS WORKED EXAMPLE 2
EXAMPLE USE OF PERFORMACE CURVE AND DUTY POINT
A certain centrifugal pump with a power rating of 10kW and an impeller diameter of
260 mm is transferring water at 20oC at a rate of 40 L/s against a pump head of
19.5m. The liquid level at suction side is lower than the liquid level at the delivery
side by 10m. Assume that the absolute pressure above each liquid is 101 kPa.
The following data describes the characteristic performance of the existing pump:
.
V (L/s) h (m) P’(kW) eff (%)
10 24.0 4.05 58
20 24.0 7.25 65
30 22.5 8.71 76
40 19.5 9.68 79
50 15.0 10.36 71
In the future, the duty for this pump will need to be increased to transfer 48 L/s of
water against a head of 22.0 m of water.
It is suggested that an impeller with a larger diameter (280 mm) may be fitted to
the existing unit.
(a) Will the pump be able to perform the required task?
(b) Will the existing electric motor be adequate and must it too, be replaced and
what would the rated power be? Chapter 7 Pumps 93
2
h p2 D
2
h p1 D1
3
P2 D 2
P Power
P1 D1
Chapter 7 Pumps 94
(b) Speed variation
.
V2 N 2
.
V1 N1
2
h p2 N
2
h p1 N1
3
P'2 N 2
P'1 N1
, hp = (0, h0)
V
5. Draw the system curve and locate the new Duty Point, 2.
Make sure that this falls on the pump curve properly.
2
h p2 D
2
h p1 D1
3
P2 D 2
P1 D1
is the flow rate (L/s)
Where V
h is the head of liquid (m)
P’ is the power (kW)
D is the impeller (mm)
Note: Standard motor rated powers – 10, 12, 15, 18.5 kW etc.
Chapter 7 Pumps 97
(L/s)
V
V h (m) P’(kW) eff (%)
10 24.0 4.05 58
20 24.0 7.25 65
30 22.5 8.71 76
40 19.5 9.68 79
50 15.0 10.36 71
Chapter 7 Pumps 98
30
28
26
24
22
h (m)
20
260 mm
18
16
14 260 mm
12
10
8
0 5 10 15 20 25 30 35 40 45 50 55
(l/s)
V
Q
Chapter 7 Pumps 99
Use the Affinity laws to calculate flow rates, heads and power for the
280 mm impeller
Data for pump performance
curve for 280mm impeller
280 .
V2 V1 1.077V1
260 V2 h2 P’2
20 280 260 mm
280 mm
18 mm
16
14 260 mm
12
10
8
0 5 10 15 20 25 30 35 40 45 50 55
(l/s)
V
Q
.
System Curve h p a V 2 c '
' h = 5.938 x 10-3 V2 + 10
.
Vsys hsys
h 19.5 (a)
Boundary V 40 p 0 10
Conditions 10 10.59
V 0 hp 10 (b)
20 12.375
30 15.344
B.C. (b) gives 10 = a’(0)2 + c’ 40 19.500
c’ = 10 50 24.84
20 280
260 mm
280 mm
18 mm system
16
14 Duty Point 1 260 mm
12 40 L/s
10 19.5 m
8
0 5 10 15 20 25 30 35 40 45 50 55
(l/s)
V
Q
20 280 mm 280 mm
system
18
300 mm
16
14 260 mm
12
10
8
0 5 10 15 20 25 30 35 40 45 50 55
(l/s)
V
Q
Selection Chart
1450 rpm
Note:
For final selection
refer to individual
performance
curves
Selection Chart
2900 rpm
Note:
For final selection
refer to individual
performance
curves