AS PER SUGGESTED LINE SIZE

FTS CONSULTANTS PVT. LTD.

PROJECT: ISP-TUTIKORIN-HWB-TUAMAN
OBJECTIVE:
Hydraulic calculation of the pump 43 P01 A/B for ascertaining the Pump Rated KW for handling Service fluid of rated capacity 6 Cum / Hr.
with required Head

REFERENCE DRAWING / DOCUMENT NO

P & ID of unit 43 ( Main Plant 1) - Drg No- 6732-02-03-04-PID-0010 SHT 1 OF 3
P & ID of unit 43 ( Main Plant 1) - Drg No- 6732-02-03-04-PID-0010 SHT 2 OF 3
Pump data sheet, Doc No- HWB/ISP/2018/01 - Page no- P-50
Plant layout drawing no. - 6732-00-08-04-EL-001 Sheet 1

INPUTS
Fluid to be Pumped 2-Ethyl Hexanol
Fluid Density 833 kg/Cum
Fluid Viscosity 9.8 cP
Pumping Temperature 40 Deg. C
Design Temperature 60 Deg. C
Static suction head considered from pump centerline 785 mm
Minimum Liquid level 333 mm
Corrioils type flow meter pressure drop considered 0.1 kg./cm^2 As per ABB data

ASSUMPTIONS
Pump Efficiency 20%

Suction vessel pressure considered 1 kg/cm2 (g) as per vessel data sheet. The operating pressure of
the vessel is 0-1 kg/cm2 (g). The vacuum condition will happen during operation of vent and vacuum
system during which the pump will not be in operation.
Pipe roughness for stainless steel Considered as As per Perry Handbook
0.03 mm.
Page No.5-24
Pipe Length for Hydraulic Calculation Considered 1.5 times from actual length in suction line

Pipe Length for Hydraulic Calculation Considered 1.5 times from actual length in Delivery line

For pump no. 43P01 A/B Fluid is pumped to 43 RV01 & 43 RV02 . Between these, 43 RV02 is the
longest line with fittings which we have considered for hydraulic calculation of pump.
L/D ratio for valves and fittings is taken reference from "CRANE BOOK"
Equiations Used in Calculation

Friction factor "f" has been calculated from Colebrook white equation (modified) equation (when
Reynold's number is > 2100) ,
f = 0.25 / [ log { €s / (IDs X 3.7) + 5.74/ Re0.9 } ] 2

Friction factor "f" has been calculated (when Reynold's number is < 2100) , f = 64 / Re

Pressure drop is calculated from Dercy Weisbach equation, as

p =(Friction Factor x pipe length x Velocity^2)/(Diameter x 2 x Gravity)
(Pressure drop Calculated Considering 100m Pipe Length)

Velocity, V=Q/A where, Q= flow in cum / hr. and A = area in m^2

Centrifugal pump power calculation = BKW = Qρgh / 3.6 × 106 × η

Where, Q= flow in Cum. / Hr. , h= differential head in meter, ρ = Density in kg/cum. , g = Gravity (9.81
m/s2) , η = efficiency of pump

TDH=Total Differential Head = Total discharge head in meter - Total suction head in meter
NPSH Available in meter = Suction Head Sum in meter - Vapour pressure in meter (P vp)
The L/D Ratio for Reducer / Expander calculated based on Crane Handbook Page No.A-26
Refer Annexure - 1 for Pipe fittings, Valve and misc Items in Pipe Routine in relation with
Calculation of System resistance

Page 3 of 10
Page 4 of 10
Annexure - 1

PUMP TAG NO. 43P01 A/B

Suction 40-ROH-0392-SS-UI (Consider Line Size 50 for Hyd. Calc)

SL No. Parameters Qty Unit Tag Nos.

1 Pipe Length 3 m
2 Spectacle Blind 1 No SBS4395
3 Ball Valve 2 No BS43739, BS43741
4 Y strainer 1 No YS43742
5 Reducer 1 No
6 Tee ( Branch) 2 No
7 90 Deg bend 1 No

Delivery 01 25-ROH-0395-SS-UI (Consider Line Size 40 for Hyd. Calc) TO 43RV01

SL No. Parameters Qty Unit Tag Nos.
1 Pipe Length 15 m
2 Reducer 1 No
3 Expander 2 No
4 Tee (Run) 2 No
5 Spectacle Blind 1 No SBG43165
6 90 Deg bend 8 No
7 Check valve 1 No NS43750
8 Ball valve 3 No BS43747, BS43756, BS43759
9 Diaphragm valve 1 No DG431109
10 Coriolis meter 1 No 43FE01
11 Orifice 0 No
12 Control valve 0 No

Delivery 02 25-ROH-0482-SS-UI TO 43RV02

SL No. Parameters Qty Unit Tag Nos.
1 Pipe Length 20 m
2 Reducer 1 No
3 Expander 2 No
4 Tee (Run) 2 No
5 Spectacle Blind 1 No SBG43167
6 90 Deg bend 8 No
7 Check valve 2 No NS43750, NS431112

8 Ball valve BS43747, BS43756, BS43759,

4 No BS431110
9 Diaphragm valve 1 No DG431113
10 Coriolis meter 1 No
11 Orifice 0 No
12 Control valve 0 No

Note:
1) Pipe lengths in Suction and Discharge are lengths Calculated from the Layout
2) Delivery 02 Line considered for Hydraulic Calculation

Page 5 of 10
 FTS CONSULTANTS PVT. LTD.
PROJECT: ISP-TUTIKORIN-HWB-TUAMAN

CALCULATIONS
Calculation basis of pump 43P01 A/B
SL.NO. DESCRIPTION DETAILS SYMBOL UNIT DATA REMARKS
1 Pipe line details
2 MOC of pipe - SS 304L
3 Suction Pipe length approx. Ls m 4.5 Note 1
4 Nominal Diameter (NB) NBs mm 50 As per Suggested Size
5 Outside diameter (OD) ODs mm 60.3 As per Suggested Size
6 Inside diameter (ID) IDs mm 52.48 As per Suggested Size
7 Thickness (Thck.) ts mm 3.91 Based on Suggested Size
8 Delivery Pipe length approx. Ld m 30
9 Nominal Diameter (NB) NBd mm 40 As per Suggested Size
10 Outside diameter (OD) ODd mm 48.3 As per Suggested Size
11 Inside diameter (ID) IDd mm 40.94 As per Suggested Size
12 Thickness (Thck.) td mm 3.68 Based on Suggested Size
13 Pipe fittings, valve and instruments quantity at Pump suction
14 Spectacle Blind - Nos. 1 As per P&ID
15 Ball Valve - Nos. 2 As per P&ID
16 Y strainer - Nos. 1 As per P&ID
17 Reducer - Nos. 1 As per P&ID
18 Tee ( Branch) - Nos. 2 As per Layout
19 90 Deg bend - Nos. 1 As per Layout
20 Details as per pipe line and PI Others parameters (suction)
21 diagram Pipe roughness €s mm 0.03 As per Input Sheet
22 Relative pipe roughness €s / IDs 0.0006
23 Entry loss co-efficient K 0.5000 As per Standard Data
24 Pipe fittings ,valve and instruments quanity at Pump delivery
25 Reducer - Nos. 1 As per P&ID
Expander Nos. 2 As per P&ID
26 Check valve - Nos. 2 As per P&ID
27 Ball valve - Nos. 4 As per P&ID
28 Coriolis meter - Nos. 1 As per P&ID
29 Tee (Run) - Nos. 2 As per P&ID
30 Spectacle Blind - Nos. 1 As per P&ID
31 Diaphragm valve - Nos. 1 As per P&ID
32 90 Deg bend - Nos. 8 As per Layout
33 Orifice - Nos. 0
34 Control valve - Nos. 0
35 Coriolis meter pressure drop - kg/cm2 0.1 From ABB data sheet
36 Others parameters (delivery)
37 Pipe roughness €d mm 0.03 As per standard data
38 Relative pipe roughness €d / IDd 0.0007
39 Exit loss co-efficient K 1.0000
40 Suction Line
41 Ball valve - NA 3
42 Y strainer - NA 250
43 90 Deg bend - NA 30 As per Crane Technical paper no 410
44 Tee ( Branch ) - NA 60
45 Reducer - NA 5.5
(L/D) Value
46 Delivery Line
47 Check Valve - NA 135
48 Ball valve - NA 3
49 Tee (Run) - NA 20
As per Crane Technical paper no 410
50 Diaphragm valve - NA 160
51 90 Deg bend - NA 30
52 Expander - NA 6.5

Page 6 of 10
 FTS CONSULTANTS PVT. LTD.
PROJECT: ISP-TUTIKORIN-HWB-TUAMAN
Friction factor, Reynold number and velocity calculation of pump 43P01 A/B
SL.NO. DESCRIPTION SYMBOL REFERENCE UNIT CALCULATION REMARKS
FLUID VELOCITY CALCULATION

SUCTION SIDE

1 Normal Flow rate Qs From process data sheet of HWB m3/hr. 5

2 Design Flow rate Qsd From process data sheet of HWB m3/hr. 6

3 Inside diameter (ID) IDs As per Suggested mm 52.48

4 Velocity of fluid Vs Velocity, V=Q/A where, Q= flow and A = area m/s 0.8

DELIVERY SIDE

5 Normal Flow rate Qs From process data sheet of HWB m3/hr. 5

6 Design Flow rate Qsd From process data sheet of HWB m3/hr. 6

7 Inside diameter (ID) IDs As per Suggested mm 40.94

8 Velocity of fluid Vs Velocity, V=Q/A where, Q= flow and A = area m/s 1.3

REYNOLD NUMBER CALCULATION

SUCTION SIDE

1 Density ρs From process data sheet of HWB kg/m3 833

2 Viscosity µs From process data sheet of HWB cP 9.8

Res Re = Fluid Velocity x Fluid Density x Actual Res > 2300, so, flow is considered as
3 Reynolds No. 3440
Diameter / Fluid Viscosity turbulent

DELIVERY SIDE

4 Density ρd From process data sheet of HWB kg/m3 833

5 Viscosity µd From process data sheet of HWB cP 9.8

Red Re = Fluid Velocity x Fluid Density x Actual Red > 2300, so, flow is considered as
6 Reynolds No. Diameter / Fluid Viscosity 4410
turbulent

FRICTION FACTOR CALCULATION

SUCTION SIDE

1 Relative pipe roughness €s / IDs 0.0006

2 from equation , f = 0.25 / [ log { €s / (IDs X 3.7) + 5.74/ Re } ] Colebrook white equation (modified)
0.9 2

3 Friction factor 0.043

DELIVERY SIDE

1 Relative pipe roughness €s / IDs 0.0007

2 from equation , f = 0.25 / [ log { €s / (IDs X 3.7) + 5.74/ Re0.9 } ] 2 Colebrook white equation (modified)

3 Friction factor 0.040

PRESSURE DROP PER 100 METER LENGTH OF PIPE LINE

SUCTION SIDE

1 Pressure drop =Friction Factor x pipe length x 2.49

Velocity^2/Diameter x 2 x Gravity

DELIVERY SIDE

1 Pressure drop =Friction Factor x pipe length x 8.0

Velocity^2/Diameter x 2 x Gravity

Page 7 of 10
 FTS CONSULTANTS PVT. LTD.
PROJECT: ISP-TUTIKORIN-HWB-TUAMAN
HYDRAULIC CALCULATION OF PUMP NO 43P01 A/B
SL.NO. DESCRIPTION SYMBOL REFERENCE UNIT CALCULATION/DATA REMARKS
BASIC INFORMATION
Transfer of Hexanol from
1 Duty/ Case From process data sheet of HWB - Feed Tank (43V01) to
Reactor (43RV02)
2 Material Pumped From process data sheet of HWB - 2-Ethyl Hexanol
3 Vapour Pressure Pvp From process data sheet of HWB mm Hg 0.46
4 Normal Flow rate Qs From process data sheet of HWB m3/hr. 5
5 Design Flow rate Qsd From process data sheet of HWB m3/hr. 6
6 Pumping temparature T1 From process data sheet of HWB °C 40
7 Density ρ From process data sheet of HWB kg/m3 833
8 Viscosity µ From process data sheet of HWB cP 9.8

9 Suction side pressure for vessel From process data sheet of HWB kg/cm^2 1.033 Considered atmospheric
pressure
Considered atmospheric
10 Discharge side pressure for vessel From process data sheet of HWB kg/cm^2 1.033 pressure
11 MOC of pipe As per P & I diagram SS 304 L
12 Schedule of pipe From process data sheet of HWB 40 S
13 Nominal Diameter (NB) NBs As per P & I diagram mm 50 For suction side
14 Inside diameter (ID) IDs As per standard data mm 52.48 For suction side
15 Nominal Diameter (NB) NBd As per P & I diagram and hydraulic calculation mm 40 For discharge side
16 Inside diameter (ID) IDd As per standard data mm 40.94 For discharge side
17 Loss of pressure due to Control valve bar 0
18 Loss of pressure due to Orifice meter mm 0
Loss of pressure due to flow
19 kg/cm^2 0.1 From ABB data sheet
meter(Corilos meter)
m 1 Equivalent
EQUIVALENT LENGTH CALCULATION
SUCTION SIDE
Sl. No. TYPE L/D Dia ( m) No. Eqv. Length(m) Remarks
1 Ball Valve 3 0.052 2 0.31
2 90 deg Elbow 30 0.052 1 1.57
3 Tee ( Branch ) 60 0.052 2 6.30
4 Y Strainer 250 0.052 1 13.12
5 Reducer 6 0.052 1 0.29
6 Spectacle blind 0 0.052 1 0.00
7 Total Suct. Val&Fit Eq. Lengths (m) 21.60
8 Length of Suct. straight pipe (m) 4.5
9 Total Equivalent Suct. length (m) 26.10
DELIVERY SIDE
Sl. No. TYPE L/D Dia ( m) No. Eqv. Length(m) Remarks
1 Ball Valve 3 0.041 4 0.49
2 90 deg Elbow 30 0.041 8 9.83
3 Tee ( Run ) 20 0.041 2 1.64
4 Check Valve 135 0.041 2 11.05
5 Reducer 7 0.041 1 0.27
6 Expander 12 0.004 2 0.09
7 Diaphragm valve 160 0.041 1 6.55
8 Total Disch. Val&Fit Eq. Lengths (m) 29.91
9 Length of Disch. straight pipe (m) 30
10 Total Equivalent Disch. length (m) 59.91
SUCTION & DISCHARGE HEADS AND PUMP POWER REQUIREMENT
SUCTION & DISCHARGE HEADS REFERENCE UNIT SUCTION DISCHARGE
Vessel Pressure m 12.649 12.649
Liq. Level m 0.333 0.000
Static Head m 0.785 5.000
Considering 30 % extra
Total Fric. Head Loss m -0.8 6.3
as safety factor
Velocity Head m -0.030 0.1
Coriolis meter m 0.000 1.2
Entry loss m -0.015 0.0
Exit loss m 0.000 0.1
Total Head metres of Fluid (abs) 12.9 25.3
DIFFERENTIAL HEAD
Discharge Head Sum m 25.27
Suction Head Sum m -12.88
TDH=Total Differential Head m 12.40
SYSTEM POWER
Efficiency (note 4 ) = (<1) 20%
Estimated Power (BKW ) (KW) 0.84
Recommended Motor KW (considering 15% mergin)= (KW) 0.97
NPSH
Suction Head Sum m 12.88
Pvp m -0.01
NPSH Available m 12.87

Page 8 of 10
CONCLUSION / SUMMARY
RESULTS OF CALCULATION
Total Differential head (As per calculation) M 12.40
Motor KW ( As per calculation ) KW 0.97
NPSH available M 12.87

Tag Number : 43 P01 A/B Quantity : 2

Service Fluid :
Type : Horizontal End Suction Back Pull Out
2-Ethyl Hexanol

Capacity (m3/hr) Head (meters)

Suction : Flooded
Normal: 5 Rated: 6
Differential : 13

Rated (kW) 1.0

Recommendation / Conclusion
Line Size in Suction and Delivery considerd higher than as shown in P&ID to keep the velocity within
recommended limit as per Standard Enginering Practice.
Reducer (Formula - 1, Crane Page A-26)

D (mm) d (mm) Ang Ang (rad) Beta

Reducer 52.51 40.9 7.5 0.131 0.78

K2 = 0.06

L/D = 5.5 from Graph at Page No. A-30

Expander (Formula - 3, Crane Page A-26)

D (mm) d (mm) Ang Ang (rad) Beta

Expander 52.51 40.9 7.5 0.131 0.78

K2 = 0.07

L/D = 6.5 from Graph at Page No. A-30