DISCUSSION

An important aspect of any design is to find the balance optimum efficiency and cost
effectiveness. Safety is also a major concern – and due consideration must be taken to
prevent hazardous disasters.

In this situation, the pipe system was designed for the worst case situation – as a
preventative measure against pipe leaks, pump malfunction due to overflow and so on.
Schedule 40 Carbon Steel was chosen as the construction material as it is economical and
has a relatively low roughness, which reduces friction.

The design limitation required that the velocity be between 1 and 3m.s-1. An initial
velocity of 1.5 m.s-1 was assumed, which returned the actual velocity as1.154 m.s-1 which
satisfies the limitation.

Errors do arise from approximations that may have been made in the design calculations
and therefore a safety factor is chosen to ensure that there is some tolerance so that the
equipment will function safely without causing a hazard. A safety factor of 10% has
been chosen to allow for flexibility in process operation as well as preventing over-
design.

The Reynolds’ Number was calculated to use in the Colebrook and White equation, to
determine the friction factor. This provides more accuracy as compared to using a graph.

Fluid head defines pressure as an equivalent static pressure of a stationary body of fluid.
Calculations are done in terms of head for convenience and easier understanding.

The depot is 14882m inland from the port, and this was assumed to be the length of the
pipe. However the change in potential across this distance is considered and added to the
total head that the pump must overcome in the form of a Static Head term. The first 100m
of the length were assumed to be flat land. The design also required specific fittings every

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3.5km which added to the Total head. The minimum level of fluid in the tank is 0.5m ,
and the feed point to the tank is 1m from the top of the tank.

All calculation were done for both the summer and winter temperatures in order to find
the ‘worst case’ scenario, which would then be the basis of the design. Summer was
found to be the worst case, as there is a higher head loss for the higher temperature.

The pumps were chosen to meet the terms of the DIN 24 256 and ISO 2858 standards for
effective flexibility and to decrease spare part stock holdings for safeguarding of the
equipment.

The first pump was placed at a position 40m away from the discharge point, which was
stipulated as being at atmospheric pressure and at sea level. It was then designed to
pump to a distance 1360m away, at a height of 60m above sea level. The second pump
was positioned at 1390m, 60m above sea level. This is 10m before the end capacity of the
first pump. This is a safety measure i.e. if for some reason the first pump does not
perform to it’s fullest, the second pump is in a position to prevent a dangerous situation.
Using similar calculations, the third pump is located at 6880m, 170m above sea level.

An important factor to consider is the Net Positive Suction Head (NPSH) of which there
are two types, Required and Available , to protect the pump and mechanical seal. The
required NPSH value is read off KSB graphs specific to the pump and its operating flow
rate. The available NPSH is calculated and must be greater than the required NPSH to
prevent cavitation in the pump which drops pump capacity as well as damages the
impeller and volute.

Control of flow rate is another important aspect of design; therefore control valves were
placed after each pump to throttle the line for good control. The 60% open is the
optimum opening, and intersects system curves at the operating flowrate (Refer Appendix
E).

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The pump curves of Δh vs. Q (see Appendix E) were plotted using points from the
CPK/HPK 80-315 pump selected from the KSB curves. The impeller diameters,
efficiencies, speeds and power of the pumps were then read off these graphs. All the
pumps were found to have a relatively high efficiency and power output.

The affinity laws were also utilized to calculate the actual speed that the pump functions
optimally. The combined pump curve is also shown –since the pumps are placed in
series, their heads are additive.